Polymer composite comprising an interfacially modified fiber and particle

ABSTRACT

Embodiments herein relate to a composite material including about 10 to 80 wt. % of a polymer phase, the polymer phase comprising a thermoplastic polymer with a density of less than about 1.9 g-m-2; and about 20 to 90 wt. % of a dispersed mixed particulate phase, the dispersed mixed particulate phase comprising a mixed particulate and about 0.005 to 8 wt. % of a coating of at least one interfacial modifier. The mixed particulate including a portion of a reinforcing fiber and a portion of a particle. The composite material having a Young&#39;s modulus of greater than 700 MPa. In various embodiments, structural building components made from the composite are included as well as additive manufacturing components made from the composite. Other embodiments are also included herein.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/928,448 filed Jul. 14, 2020 which is a divisional of U.S. patentapplication Ser. No. 16/251,301 filed Jan. 18, 2019, which is adivisional of Ser. No. 14/771,175 filed Aug. 27, 2015, which is aNational Stage Entry of PCT/US2014/026932 filed Mar. 13, 2014, whichclaims priority to U.S. Provisional Patent Application 61/782,516, filedon Mar. 14, 2013 and titled “A POLYMER COMPOSITE COMPRISING ANINTERFACIALLY MODIFIED FIBER AND PARTICLE”. The entire disclosures ofall being incorporated herein by reference.

FIELD

Embodiments herein relate to composites including a polymer phase and adispersed mixed particulate phase comprising a mixed particulate.

BACKGROUND

Substantial attention has been paid to the creation of compositematerials with unique properties. Included in this class of materialsare materials with improved viscoelastic character, varying densities,varying surface characteristics and other properties which may be usedto construct a composition with improved properties. Composite materialshave been made in the past by combining generally two dissimilarcomponents to obtain beneficial properties from both components. A truecomposite is unique because the interaction and engineered combinationof the components provides the best properties and characteristics fromboth components.

Many types of composite materials are known. Generally, the artrecognizes that combining metals of certain types and proportions toform an alloy that provides unique properties in the metal/metal alloymaterials with different properties than the metals alone. Metal/ceramiccomposites have been made typically involving combining metal powder orfiber with clay materials that can be sintered into a metal/ceramiccomposite.

Combining typically a thermoplastic or a thermosetting polymer phasewith a reinforcing powder or fiber produces a range of filled materialsand, under the correct processing conditions, can form a true polymercomposite. In contrast, a filled polymer, with the additive as filler,cannot display composite properties. A filler material typically iscomprised of inorganic materials that act as either pigments orreplacement for the polymer component. Fillers are often a substitutionfor a more expensive component in the composition. A vast variety offiber-reinforced composites have been made typically to obtain fiberreinforcement properties used to modify only the mechanical propertiesof the polymer in a specific composite.

Polymer materials have been combined with cellulosic fiber to makeextruded materials. However, such materials have not successfully beenused in the form of a structural member that is a direct replacement forwood or other materials, such as aluminum and concrete, for temporarystructures that are useful for military, commercial or building materialapplications. Such materials can be in the form of a decorative orstructural material or member. Common extruded thermoplastic compositematerials cannot provide thermal and structural properties similar towood or other structural materials. These extruded materials fail tohave sufficient modulus, compressive strength, and coefficient ofthermal expansion that matches wood to produce a direct replacementmaterial. Further, many prior art extruded composites must be milledafter extrusion to a final useful shape. One class of composite, apolyvinyl chloride/wood flour material, poses the added problem thatwood dust, which can accumulate during manufacture, tends to beexplosive at certain concentrations of very fine, airborne, wood dust orpowder.

Many of these materials containing polymer and particulate areadmixtures of separate components and are not true composites.Admixtures are relatively easily separable into the constituent partsand, once separated, the component parts display the individualproperties of the components. A true composite resists separation anddisplays enhanced and often different properties of the input materialswhereas the individual input materials often do not display the enhancedproperties. A true composite does not display the properties of theindividual components but displays the unique character of the compositeas a whole.

SUMMARY

Embodiments herein relate to composites including a polymer phase and adispersed mixed particulate phase comprising a mixed particulate. Themixed particulate can include a portion of a reinforcing fiber(including, but not limited to cellulosic or wood fibers) and a portionof particles such as, but not limited to, hollow glass microspheres,glass particles, mineral or ceramic particulates. Embodiments hereinalso include methods of making and using the composite as well asapplications of the materials.

In various embodiments, a composite material is included. The compositematerial including about 10 to 80 wt. % of a polymer phase, the polymerphase comprising a thermoplastic polymer with a density of less thanabout 1.9 g-m², and about 20 to 90 wt. % of a dispersed mixedparticulate phase, the dispersed mixed particulate phase comprising amixed particulate and about 0.005 to 8 wt. % of a coating of at leastone interfacial modifier. The mixed particulate can include a portion ofa reinforcing fiber and a portion of a particle. The composite materialcan have a Young's modulus of greater than 700 MPa.

In some embodiments, the material of the invention can be providedthrough a selection of nonmetallic particle specie, particle size(P_(s)) distribution, molecular weight, and viscoelastic character andprocessing conditions. The particles can have a specific and novelparticle morphology that cooperates with the components of the inventionto provide the needed properties to the composite. The material canattain adjustable chemical/physical properties through particleselection and polymer selection. The resulting composite materials canexceed the contemporary composites in terms of various properties suchas density, surface character, reduced toxicity, improved malleability,improved ductility, improved viscoelastic properties (such as tensilemodulus, storage modulus, elastic-plastic deformation and others)vibration or sound, structural strength and/or machine moldingproperties. In various embodiments, the packing of the selected particlesizes (P_(s), P_(s) ¹, etc.), distribution population particles and theselection of the particulate or mixed non-metal, inorganic, ceramic ormineral particulate, can be used to obtain enhanced properties. Thematerials of the invention are well suited for many applications,including, but not limited to, the manufacture of decorative andstructural members used in building applications as well as in additivemanufacturing systems as a filament or other type of feedstock.

This summary is an overview of some of the teachings of the presentapplication and is not intended to be an exclusive or exhaustivetreatment of the present subject matter. Further details are found inthe detailed description and appended claims. Other aspects will beapparent to persons skilled in the art upon reading and understandingthe following detailed description and viewing the drawings that form apart thereof, each of which is not to be taken in a limiting sense. Thescope of the present invention is defined by the appended claims andtheir legal equivalents.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be more completely understood in connection with thefollowing drawings, in which:

FIGS. 1A and 1B show a building panel in accordance with variousembodiments herein.

FIGS. 2A-2C show a second embodiment of a building panel of theinvention using the composite material with tongue and groove joinery.

FIGS. 3A-3B show a cross-sectional view of siding members made using acomposite in accordance with various embodiments herein.

FIG. 4 shows a cross sectional view of a further embodiment of a sidingmember.

FIG. 5 shows a cross-sectional view of a further embodiment of a sidingmember.

FIGS. 6-8 show further embodiments of siding members with alternativeprofiles.

FIGS. 9 and 10 show a hollow profile structural member using thecomposite material.

FIG. 11 shows a solid dimensional structural member using the compositematerial.

FIG. 12 shows an enclosure formed with structural members using thecomposite material.

FIG. 13 shows detail from a view of a portion of a wall from theenclosure of FIG. 12.

While the invention is susceptible to various modifications andalternative forms, specifics thereof have been shown by way of exampleand drawings, and will be described in detail. It should be understood,however, that the invention is not limited to the particular embodimentsdescribed. On the contrary, the intention is to cover modifications,equivalents, and alternatives falling within the spirit and scope of theinvention.

DETAILED DESCRIPTION

The embodiments described herein are not intended to be exhaustive or tolimit the invention to the precise forms disclosed in the followingdetailed description. Rather, the embodiments are chosen and describedso that others skilled in the art can appreciate and understand theprinciples and practices.

It is desirable to have a material that has beneficial propertiesincluding one or more of tunable density, reduced toxicity, improveddistortion under thermal and mechanical stress, improved ductility,improved viscoelastic properties (such as tensile modulus, storagemodulus, elastic-plastic deformation and others) electrical/magneticproperties, structural properties and/or machine molding properties withsubstantially reduced wear on processing equipment.

As described above, polymer materials have been combined with cellulosicfiber to make extruded materials. However, these materials have not beentrue composites and thus do not provide the beneficial properties of atrue composite. Thus, while a substantial amount of work has been doneregarding composite materials generally, the use of a dispersed fiber,with nonmetallic particles (such as glass particles, hollow glassspheres, glass micro-bubbles, or mineral particles) in a polymer phaseto produce a true composite material has not been previously obtained.

Embodiments herein relate to novel composites made by combining apolymeric phase and a mixed dispersed particulate phase comprising areinforcing fiber (such as a cellulosic or wood fiber), a particulate(s)(such as a hollow glass microsphere, a glass particle, a mineral or aceramic), and an interfacial modifier. In one embodiment thesecomponents provide a structural composite having improved and novelproperties, for example, for structural requirements for permanent aswell as temporary buildings and to achieve novel physical electricalsurface and viscoelastic properties. Further, the novel composites canbe used as a filament, feedstock, for additive manufacturing (AM)solutions, commonly called 3-D or 3 dimensional printing, is used forthe creation of parts used in the processes of designing andmanufacturing products and for the direct manufacture of end-user parts.In one aspect, AM systems utilize fused deposition modeling (FDM) andinkjet-based, for example PolyJet™ technologies, to enable theproduction of prototypes and tools used for production and manufacturedgoods directly from three-dimensional (3D) CAD files or other 3Dcontent. Desktop 3D printers, such as for example MAKERBOT® REPLICATOR®2 or other similar types of printers, for idea and design development,and a range of systems for rapid prototyping, and production systems fordirect digital manufacturing under the uPrint, Mojo, Objet, Dimension,Fortus, and Solidscape brands for larger types of printers for additivemanufacturing. AM or 3-D printing solutions are used in the aerospace,apparel, architecture, automotive, business machines products, consumer,defense, dental, electronics, educational institutions, heavy equipment,jewelry, medical, and toys industries.

In an embodiment the composite material uses a proportion of cellulosicfiber in the mixed dispersed particulate phase. The cellulosic fibercommonly comprises fibers having a high aspect ratio made of cells withcellulosic cell walls. In one aspect, the aspect ratio can be in a rangeof 1:100 that can include mixtures of many aspect ratios from 1:1,1:1.5, 1:3, 1:10, 1:50, and/or 1:100, wherein any of those ratios canform the lower or upper bound of a range describing the aspect ratio.During the composite forming process of the embodiment, the cell walls,lumen, and cellulosic fiber are not substantially compressed andinterfacial modifiers, but not polymers, are introduced into theinterior void volume of the cellulosic wood fiber cells. In someembodiments, the viscosity of the interfacial modifier can be relativelylow, which allows for penetration into the lumen of the cellulosicfiber. It is believed that coating of the lumen interior of cellulosicfibers reduces the friction of the interior surface of fiber permittingsmaller glass beads or smaller hollow glass spheres to embed within thelumen of the fiber. This aspect of the composite formation is believedto be in contrast to the past technology where the polymer material didinvest and substantially permeate the wood fiber internal structure suchas the lumen.

The cellulosic material for the fiber particulate portion of thecomposite material may be derived from a variety of sources includinghard and soft wood products and by-products, sugar cane, cotton, flaxand other known sources of cellulosic materials. In an embodiment, pineis a source of cellulosic material. In another embodiment, maple is asource of cellulosic material. Mixtures of cellulosic material for thefiber portion, such as, for example, hardwood or soft wood blends, orwood fiber with other fiber such as cotton or flax, of the composite arecontemplated as being useful embodiments. A source of cellulosic fibercomprises wood fiber, which can be a product or by-product of themanufacture of lumber or other wood products.

A portion of spherical hollow glass microsphere particulate having aparticle size ranging from about 10 microns to about 1,500 microns maybe used in the dispersed particulate phase of the composite material.Other useful sizes of hollow glass microspheres are 10 to 100μ, 10 to75μ, 10 to 50μ, or 10 to 25μ. The smaller hollow glass microspheres maypermeate and migrate into the lumen of the cellulosic fiber. The maximumsize is such that the particle size (P_(s)) of the particle is less than20% of either the least dimension or the thinnest part under stress in ashaped article. Such particles can be substantially hollow andspherical.

Both thermoplastic and thermosetting resins can be used in variousembodiments. Such resins are discussed in more detail below. In the caseof thermoplastic resins, the composites are specifically formed byblending the particulate with an interfacial modifier prior to mixingwith thermoplastic polymer and then forming the material into a finishedcomposite, such as a pellet comprising an interfacially modified woodfiber coated surface and an interfacially modified glass particle coatedsurface associating with, but not covalently bonding to, the polymer.Thermosetting composites are made by coating the particulate withinterfacial modifier with an uncured material and then curing thematerial into a finished composite material such as a pellet.

The fiber and particulate material(s) can be coated with an interfacialsurface chemical treatment that supports or enhances the finalproperties of the composite. The interfacial modifier coating provides anew surface on the wood fiber particulate and other particulate, forexample, hollow glass microsphere, glass bead, inorganic mineral, metal,or ceramic material. This new surface on the particulate has a designedminimal interaction or reactivity with the polymer or polymers of thepolymer phase of the composite and, in an embodiment, this surfaceprovided by the interfacial modifier enables the fiber and theparticulate portions to become immiscible within the polymer phase. Theinterfacial modifier on the surface of the particulate enables theparticulate bulk to interact with the polymer and other particulateportions exclusively at the interfaces of said particulate and saidpolymer. In one aspect the individual glass and cellulosic particulatesmay slide among each other at the interfaces. In another aspect theindividual particulates may self-order themselves to obtain very highpacking density within the polymer phase. In another aspect theparticulate portion may migrate and self-order within the lumen of thecellulosic fiber. Particulate within the lumen of the cellulosic fiberenables the fiber to retain the benefits of its fiber structure andprovides attributes, such as for example, resilience, unique acousticalproperties, thermal properties such as insulation, electrical propertiessuch as insulation, impact properties etc. to the composite material asan entity. This property of the interfacially modified surface on theparticulate and wood fiber phases allows the composite to be tuned ormodified to have specific properties of either the particulate, woodfiber or polymer depending on the final application or use of thecomposite material.

A composite is more than a simple admixture of different types ofmaterial. A composite is defined as a combination of two or moresubstances intermingled in various percentages of the composition, inwhich each component of the composition results in properties that areadditive or superior to those of the separate constituents of thecomposite. In a simple admixture the mixed material has littleinteraction and little property enhancement. For example, in a compositeone of the materials may be chosen to increase or decrease stiffness,fiber reinforcement, strength or to vary density of the resultingcomposite material.

Atoms and molecules can form bonds with other atoms or molecules using anumber of mechanisms. Such bonding can occur between the electron cloudof an atom or molecular surfaces including molecular-molecularinteractions, atom-molecular interactions and atom-atom interactions.Each bonding mechanism involves characteristic forces and dimensionsbetween the atomic centers even in molecular interactions. The importantaspect of such bonding force is strength, and the variation of bondingstrength over distance and directionality. The major forces in suchbonding include ionic bonding, covalent bonding and the van der Waals'(VDW) types of bonding.

Ionic radii and bonding occur in ionic species such as Na⁺Cl⁻, Li⁺F⁻.Such ionic species form ionic bonds between the atomic centers. Suchbonding is substantial, often substantially greater than 100 kJ-mol⁻¹often greater than 250 kJ-mol⁻¹. Further, the interatomic distance forionic radii tend to be small and on the order of 1-3 Å.

Covalent bonding results from the overlap of electron clouds surroundingatoms forming a direct covalent bond between atomic centers. Thecovalent bond strengths are substantial, are roughly equivalent to ionicbonding and tend to have somewhat smaller interatomic distances.

The varied types of van der Waals' forces are different than covalentand ionic bonding. These van der Waals' forces tend to be forces betweenmolecules, not between atomic centers. The van der Waals' forces aretypically divided into three types of forces including dipole-dipoleforces, dispersion forces and hydrogen bonding.

TABLE 1 Summary of Chemical Forces and Interactions Type of StrengthInteraction Strength Bond Nature Proportional to: Covalent bond VeryComparatively r⁻¹ strong long range Ionic bond Very Comparatively r⁻¹strong long range Ion-dipole Strong Short range r⁻² VDW Dipole-Moderately Short range r⁻³ dipole strong VDW Ion- Weak Very r⁻⁴ induceddipole short range VDW Dipole- Very Extremely r⁻⁶ induced dipole weakshort range VDW London Very Extremely r⁻⁶ dispersion forces weak^(a)short range ^(a)Since VDW London forces increase with increasing sizeand there is no limit to the size of molecules, these forces can becomerather large. In general, however, they are very weak.

Dipole-dipole forces arise by the separation of charges on a moleculecreating a generally or partially positive and a generally or partiallynegative opposite end. The forces arise from electrostatic interactionbetween the molecule negative and positive regions. Hydrogen bonding isa dipole-dipole interaction between a hydrogen atom and anelectronegative region in a molecule, typically comprising an oxygen,fluorine, nitrogen or other relatively electronegative (compared to H)site. These atoms attain a dipole negative charge attracting adipole-dipole interaction with a hydrogen atom having a positive charge.Dispersion force is the van der Waals' force existing betweensubstantially non-polar uncharged molecules. While this force occurs innon-polar molecules, the force arises from the movement of electronswithin the molecule. Because of the rapidity of motion within theelectron cloud, the non-polar molecule attains a small but meaningfulinstantaneous charge as electron movement causes a temporary change inthe polarization of the molecule. These minor fluctuations in chargeresult in the dispersion portion of the van der Waals' force.

Such VDW forces, because of the nature of the dipole or the fluctuatingpolarization of the molecule, tend to be low in bond strength, typically50 kJ mol⁻¹ or less. Further, the range at which the force becomesattractive is also substantially greater than ionic or covalent bondingand tends to be about 3-10 Å.

In an embodiment, we have found that the unique combination of woodfiber particulate, the varying but controlled wood fiber and particlesize within the particle and fiber components of the particulate phase,and the modification of the interaction between the wood fiber and theparticulate phase and the polymer phase, result in the creation of aunique van der Waals' bonding. The van der Waals' forces arise betweenparticulate atoms/crystals in the particulate/fiber and the polymers arecreated by the combination of particulate size, polymer and interfacialmodifiers in the composite.

In the past, materials that are characterized as “composite” have merelycomprised a polymer filled with particulate with little or no van derWaals' interaction between the particulate filler material. InApplicants' embodiment, it is believed the interaction between theselection of wood fiber size, inorganic particle size distribution withthe interfacially modified particulate and interfacially modified woodfiber particulate enables the wood fiber and particulate phase toachieve an intermolecular distance that creates a substantial van derWaals' bond strength. The current state of the art materials, havingminimal if any viscoelastic properties, do not achieve such a truecomposite structure. This leads us to conclude that this intermoleculardistance is not attained in the current state of the art. In thediscussion above, the term “molecule” can be used to relate to aparticle or particulate, a particle comprising non-metal crystal, aglass bead, a glass microsphere, a hollow glass microsphere, wood fiberor an amorphous aggregate, among other molecular or atomic units orsub-units of fibers, non-metal or inorganic mixtures. In the compositesof the embodiments, the van der Waals' forces occur between collectionsof atoms that act as “molecules” in the form of mineral, inorganic,cellulosic or non-metal atom aggregates.

The composite material can be characterized by a composite havingintermolecular forces between particles is about 30 kJ-mol⁻¹ and a bonddimension of 3-10 Å. The particulate in the composite material of theembodiment has a range of particle sizes such that about at least 5wt.-% of particulate are in the range of about 10 to 500 microns andabout at least 5 wt.-% of particulate are in the range of about 10 to250 microns, and a polymer, the composite having a van der Waals'dispersion bond strength between molecules in adjacent particles of lessthan about 4 kJ-mol⁻¹ and a bond dimension of 1.4 to 1.9 Å or less thanabout 2 kJ-mol⁻¹ and the van der Waals' bond dimension is about 1.5 to1.8 Å.

In an embodiment, the dispersed and mixed particulate phase with atleast a portion of glass particulate and a portion of fiber particulateis usually much stronger and stiffer than the polymer matrix. Thedispersed and mixed particulate phase gives the composite material itsgood properties such as, for example, reinforcement and structuralproperties. The polymer matrix holds the reinforcing particulate in anorderly high-density pattern. Because the reinforcing particulates areusually discontinuous, the matrix also helps to transfer load among theparticulates. The reinforcing particulates, such as for example, fibersand particles, can be used in a wide variety of shaped articles madefrom the composite material, such as for example, building panels. In anembodiment, the composite material can be shaped into replacementstructures or reinforcing components for other materials such as, forexample, lumber, metal, or concrete. The processing can aid in themixing of the reinforcement particulate. The dispersed and mixedparticulate phase may comprise greater than about 10 wt. %, greater thanabout 15 wt. %, greater than about 20 wt. % or about 15 wt. %-65 wt. %of the composite. To aid in the mixture, an interfacial modifier canhelp to overcome the forces that prevent the matrix from forming asubstantially continuous phase of the composite.

In an embodiment the dispersed mixed particulate phase may range fromabout 15.0 to 90.0 wt. % from about 15.0 to 80.0 wt. %, from about 15.0to 70.0 wt. % of the composite. In one embodiment, the dispersed mixedparticulate phase is at least about 40 vol. %, at least about 50 vol. %,at least about 60 vol. %. In an embodiment the hollow glass, or solidglass microsphere particulate may range from 20.0 to 80.0 vol. % of thecomposite and the wood fiber particulate from 80.0 to 20.0 vol. %. In anembodiment within the mixed particulate phase, the hollow glass or solidmicrosphere or bead particulate may range from 5.0 to 90.0 vol. % of theparticulate phase and the wood fiber particulate from 95.0 to 10.0 vol.%.

In an embodiment of a high volume fraction particle phase, on the highend of particle loading and density, for example, such as, 85 vol. % inthe polymer with 90 vol. % being a solid glass spherical particle, therecould be as high as 92 wt. % particle fraction.

In an embodiment of a low density volume fraction particle phase, on thelow end of particle loading and density for example, such as, 40 vol. %particle in the polymer with 90% being a low density hollow glassmicrosphere of 0.2 g/cc density, there could be as low as 15 wt. %particle fraction.

The composite properties arise from the intimate association of thepolymer and particulate obtained by use of careful processing andmanufacture. An interfacial modifier is an organic material, in someexamples an organo-metallic material, that provides an exterior coatingon the particulate to provide a surface that can associate with thepolymer promoting the close association of polymer and particulate butwith no reactive bonding, such as covalent bonding for example, ofpolymer to particulate, particulate, such as fiber, to a differentparticulate, such as a glass particle or a glass bubble. In oneembodiment, the coating of interfacial modifier at least partiallycovers the surface of the particulate. In another embodiment, thecoating of interfacial modifier continuously and uniformly covers thesurface of the particulate, in a continuous coating phase layer. Minimalamounts of the modifier can be used including about 0.005 to 8 wt.-%,about 0.02 to 6.0, wt. %, about 0.02 to 3.0 wt. %, about 0.02 to 4.0 wt.% or about 0.02 to 5.0 wt. %.

Interfacial modifiers used in the application fall into broad categoriesincluding, for example, stearic acid derivatives, titanate compounds,zirconate compounds, hafnium compounds, samarium compounds, strontiumcompounds, neodymium compounds, yttrium compounds, phosphonatecompounds, aluminate compounds. Aluminates, phosphonates, titanates andzirconates useful contain from about 1 to about 3 ligands comprisinghydrocarbyl phosphate esters and/or hydrocarbyl sulfonate esters andabout 1 to 3 hydrocarbyl ligands which may further contain unsaturationand heteroatoms such as oxygen, nitrogen and sulfur. Preferably thetitanates and zirconates contain from about 2 to about 3 ligandscomprising hydrocarbyl phosphate esters and/or hydrocarbyl sulfonateesters, preferably 3 of such ligands and about 1 to 2 hydrocarbylligands, preferably 1 hydrocarbyl ligand.

In one embodiment the interfacial modifier that can be used is a type oforgano-metallic material such as organo-cobalt, organo-irons,organo-nickels, organo-titanate, organo-aluminates, organo-strontium,organo-neodymium, organo-yttrium, or organo-zirconates. The specifictype of organo-titanate, organo-aluminates, organo-strontium,organo-neodymium, organo-yttrium, organo-zirconates which can be usedand which be referred to as organo-metallic compounds are distinguishedby the presence of at least one hydrolysable group and at least oneorganic moiety. Mixtures of the organo-metallic materials may be used.The mixture of the interfacial modifiers may be applied inter- orintra-particle, which means at least one particle may has more than oneinterfacial modifier coating the surface (intra), or more than oneinterfacial modifier coating may be applied to different particles orparticle size distributions (inter). These types of compounds may bedefined by the following general formula:

M(R₁)_(n)(R₂)_(m)

wherein M is a central atom selected from Ti, Al, and Zr; R₁ is ahydrolysable group; R₂ is a group consisting of an organic moiety;wherein the sum of m+n must equal the coordination number of the centralatom and where n is an integer ≥1 and m is an integer ≥1.

Particularly R₁ is an alkoxy group having less than 12 C atoms. Otheruseful groups are those alkoxy groups, which have less than 6 C, andalkoxy groups having 1-3 C atoms. R₂ is an organic group includingbetween 6-30, preferably 10-24 carbon atoms optionally including one ormore hetero atoms selected from the group consisting of N, O, S and P.R₂ is a group consisting of an organic moiety, which is not easilyhydrolyzed and often lipophilic and can be a chain of an alkyl, ether,ester, phospho-alkyl, phospho-alkyl, phospho-lipid, or phospho-amine.The phosphorus may be present as phosphate, pyrophosphato, or phosphitogroups. Furthermore, R₂ may be linear, branched, cyclic, or aromatic.

For purposes of this disclosure, wood fiber, in terms of abundance andsuitability, can be derived from either soft woods or evergreens or fromhard woods commonly known as broad leaf deciduous trees as described inU.S. Pat. No. 5,441,801, herein incorporated by reference in itsentirety. Hard woods or soft wood are useful in the embodiments. Softwoods are characterized by fibers that are longer; contain highpercentages of lignin and lower percentages of hemicellulose than hardwoods. While soft wood may be a source of fiber, additional fibermake-up can be derived from a number of secondary or fiber reclaimsources including bamboo, rice, sugar cane, and recycled fibers fromnewspapers, boxes, computer printouts, etc.

However, the primary source for wood fiber comprises the wood fiberby-product of sawing or milling soft woods such as sawdust or millingtailings. Such wood fiber has a regular reproducible shape and aspectratio. The fibers based on a random selection of about 100 fibers arecommonly at least 3 mm in length, 1 mm in thickness and commonly have anaspect ratio ranging from 1:3 to 1:8, or higher. Preferably, the fibersare 1 to 10 mm in length, 0.3 to 1.5 mm in thickness with an aspectratio between 2 and 7, preferably 2.5 to 6.0. In other embodiment thesize of the wood fibers may be at least 75, 106, 150 or 425 microns inlength. Moisture content of the wood fiber will range from 4%, 5%, 6%,7%, 8%, 9%, 10% 11%, or 12% depending on the species. Bulk densityranges from 0.128, 0.160, 0.192, 0.224, 0.256, and 0.288 to 0.320 g/cm³depending on species.

The fibers are derived from processes common in the manufacture of woodproducts such as, for example, windows and doors. Wooden members arecommonly ripped or sawed to size in a cross grain direction to formappropriate lengths and widths of wood materials. The by-product of suchsawing operations is a substantial quantity of sawdust. In shaping aregular shaped piece of wood into a useful milled shape, wood iscommonly passed through machines which selectively remove wood from thepiece leaving the useful shape. Lastly, when shaped materials are cut tosize and mitered joints, butt joints, overlapping joints, mortise andtenon joints are manufactured from pre-shaped wooden members,substantial waste trim is produced. Such large trim pieces are commonlycut and machined to convert the larger objects into wood fiber havingdimensions approximating sawdust or mill tailing dimensions. The woodfiber can be blended regardless of particle size and used to make thecomposite. The fiber stream can be pre-sized to a range or can be sizedafter blending. Further, the fiber can be pre-pelletized before use incomposite manufacture.

Such sawdust material can contain substantial proportions of wastestream by-products. Such by-products include waste polyvinyl chloride orother polymer materials that have been used as coating, cladding orenvelope on wooden members; recycled structural members made fromthermoplastic materials; polymeric materials from coatings; adhesivecomponents in the form of hot melt adhesives, solvent based adhesives,powdered adhesives, etc.; paints including water based paints, alkydpaints, epoxy paints, etc.; preservatives, anti-fungal agents,anti-bacterial agents, insecticides, etc.; and other waste streamscommon in the manufacture of wooden doors and windows.

The total waste stream content of the wood fiber materials is commonlyless than 25 wt-% of the total wood fiber input into the wood fibercomposite material. Of the total waste recycle, approximately 10wt.-percent of that can comprise a vinyl polymer commonly polyvinylchloride. Commonly, the intentional recycle ranges from about 1 to about25 wt-%, preferably about 2 to about 20 wt-%, or from about 3 to about15 wt-% of contaminants based on the sawdust. The sawdust preferably hasa density of 0.15 g/cc to ±0.30 g/cc.

Other fibers, such as glass, boron, carbon, aramid, metal, polyester,nylon, etc. for example, are contemplated as additives to provide othercharacteristics to the wood fiber and glass bubble composite. Thesefibers may be either used in addition, as reinforcement as additionalfibers, or as replacement fibers for the wood fiber or glass bubblecomponent of the composite material. These fibers can be coated withinterfacial modifier. These other fibers may provide additionalstructural support or other functional aspects to support particularuses. Examples of other uses are as building protection such as, forexample, from the environment (e.g. wind, rain, snow, temperature, heat,etc.) or stresses (e.g. earthquake, electromagnetic radiation,projectiles, etc.). Optionally, some of these fibers may be coated withthe interfacial modifier depending on the end purpose of the shapedarticle or composite material.

For the purpose of this disclosure, the “dispersed mixed particulatephase” of the composite material refers to a fiber and a particle beingpresent in the composite material. The function of interest for thedispersed mixed particulate phase to determines the proportion of thefiber and the portion of the inorganic particle. A portion of fiber maybe at least 10%, 20%, 30%, 40%, or 50% of volume or weight fraction ofthe dispersed mixed particulate phase, and a portion of inorganicparticle may be at least 5%, 10%, 20%, 30%, or 40%. The function ofinterest, in an embodiment a structural composite, determines theportions of the fiber and inorganic particulate within the dispersedmixed particulates

Regarding the particulate material, the term a “majority of theparticulate” indicates that while the particulate can contain some smallamount of small fines and some particles that are large with respect tothe recited range, the majority (greater than 95%, 90%, 85%, etc.) fallwithin the recited range and contribute to the physical properties ofthe composite.

Glass particulate, as described in published U.S. Patent Application2010/0279100, commonly owned by assignee, and herein incorporated byreference in its entirety, can be combined with a second particulatesuch that the second particle differs from the glass by at least ±5microns, or has a particle size such that according to the formulaP_(S)≥2 P_(S) ¹ or P_(S)≤0.5 P_(S) ¹ wherein P_(S) is the particle sizeof the hollow glass microsphere and P_(S) ¹ is the particle size of theparticulate.

For the purposes of this disclosure, the term “aspect ratio” is definedas length/diameter, or L/D, of one fiber.

For the purpose of this disclosure, the term “inorganic” relates to amaterial substantially free of carbon in the form or organic carbon orcovalently bonded carbon compounds. Accordingly, compounds such ascalcium carbonate or sodium bicarbonate are considered inorganicmaterials while most organic compounds including small molecules such asmethane, ethane, ethylene, propylene, related polymer species, etc., arecommonly considered organic materials.

For the purpose of this disclosure, the term “particle” and“particulate” are largely synonymous relate to a material that issubstantially different than the polymer phase. “Particle” and“particulate” are used in this disclosure to relate to fiber (wood,synthetic, metal or natural) and to materials such as metals, minerals,ceramics, synthetic beads or synthetic hollow spheres or microsphere. Ina packed state, this particulate has an excluded volume of about 13 to61 vol. % or about 30 to 75 vol.-%. Alternatively, the particulate canhave greater than about 30 vol. %, greater than about 40 vol. % or about40 to 70 vol.-% particle loading. In the embodiments, the particulatecan comprise two, three or more particulates sources, in a blend ofmaterials of differing chemical and physical nature. Such materials mayhave a range of sizes for 10 to 4000 microns and may be used incombination with the wood fiber particulate.

For the purpose of this disclosure the term “profile” refers to theshape of a decorative or structural component that is made by extrudingthe composite material through a die that has an opening of the“profile” shape or made by injection molding the composite material tohave the “profile” shape.

For the purpose of the disclosure the term “fenestration” refers to anyopening in a building for human habitation that can be used as a windowor door or as an installation location for a window or door

For the purpose of this disclosure the term “module, enclosure or hut”refers to a protected and useful place for human activity.

For the purpose of this disclosure the term “panel” refers to agenerally planar component of a structure derived from the compositethat can be used as a structural or decorative component. Such panelscan be used as a decorative siding or as a load bearing structuralmember.

Particle Morphology Index

The interfacial modification technology depends on the ability toisolate the particles or particulate from that of the continuous polymerphase. The isolation of the particulates requires placement of acontinuous molecular layer(s) of interfacial modifier to be distributedover the surface of the particles. In an embodiment, the interfacialmodifier would be distributed over all or part of the surface of thewood fiber and the surface of a solid or hollow glass microsphere. Oncethis layer is applied, the behavior at the interface of the interfacialmodifier to polymer dominates the physical properties of the composite(e.g. tensile, rheology, viscosity, and elongation behavior) while thebulk nature of the particle dominates the bulk material characteristicsof the composite (e.g. density, thermal conductivity, compressivestrength, structural strength). The correlation of particulate bulkproperties to that of the final composite is especially strong due tothe high volume percentage loadings of particulate phase associated withthe technology.

There are two key attributes of the particle surface that dictate theability to be successfully interfacially modified: 1) The overallsurface area of the particles on a large scale; large being defined asabout 100× or more compared to the molecular size of the interfacialmodifier, and 2) particle surface characteristics that are on the orderof the size, characteristics, and properties of the interfacial modifierbeing applied.

The following particle morphology attributes specifically contribute tothe ability to effectively interfacially modify the particles. Combiningthe different particle attributes we have derived a particle morphologyindex. Discussion will reveal that vastly different particle types canbe effectively modified from large, smooth, round, and impervioussurface types (low particle morphology index) to small, rough, irregularand porous (high particle morphology index):

Particle Size (P_(s))

A wide range of glass (e.g. beads, spheres, hollow glass bubbles, etc.)or other particle (e.g ceramic or mineral) can be effectivelyinterfacially modified. Successful modification has been completed withparticles with a major dimension as small as −635 US mesh (<20μ) toparticles as large as −40US mesh (−425μ). Undoubtedly, larger particlesizes can be effectively modified (1,500μ or greater). The absolute sizeof the particle being modified is not important; the relative size ofthe major dimension of the largest particle to the minimum criticaldimension of the end article is more important. Our composite experienceguides us that the major dimension of the largest particles should notbe more than ⅕^(th) (20%) of the minimum critical dimension of the endarticle.

As the particles become smaller the particulate surface area increases.For smooth spheres of a constant density, there is 28 times more surfacearea in spheres of 15 μm than 425 μm diameter within a given mass ofmaterial. There is 100 times the surface area for particles of 15 μmdiameter compared to 1500 μm.

Dosage levels of interfacial modifier have been effectively adjusted tocompensate for changes in surface area due to particle size shifts.

Particle Shape/Aspect Ratio (P_(sh))

The benefit of interfacial modification is independent of overallparticle shape. Particles with an aspect ratio of 1 (hollow glassbubbles of iM30K and ceramic G200 microspheres from 3M, solid glassbeads 2429A, 3000A or 5000a from Potters) to 10 (some particularlyirregularly shaped garnet) have been favorably interfacially modified.In other embodiments, the aspect ratio of the particulate can be in arange of 1:100 that can include mixtures of many aspect ratios from 1:1,1:1.5, 1:3, 1:10, 1:50, and/or 1:100, wherein any of those ratios canform the lower or upper bound of a range describing the aspect ratio. Inan embodiment, particulate comprising hollow glass bubbles, ceramicmicrospheres, or solid glass beads/particles may range in average sizesfrom 1 to 12μ, 7 to 10μ, 9 to 30μ, 30 to 50μ, or 70 to 100μ depending onthe source and size distribution of the of the particulate. The currentupper limit constraint is associated with challenges of successfuldispersion of fibers within laboratory compounding equipment withoutsignificantly damaging the high aspect ratio fibers. Furthermore,inherent rheological challenges are associated with high aspect ratiofibers. With proper engineering, the ability to successfully compoundand produce interfacially modify fibers of fiber fragments with aspectratio in excess of 1:100 is envisioned.

At a given minor axis particle dimension, the relationship of particleaspect ratio to surface area is determined, using a two dimensionalprofile, is given by:

Sphere = π D²; and ARobject = π D²(r_(a) + 0.5);

wherein D is particle size (P_(s)) or diameter, r_(a) is aspect ratio.

For a given minor dimension, the surface area of a particle with anaspect ratio of 10 has 10.5 times the surface area than a sphericalparticle. Dosage levels of interfacial modifier can be adjusted tocompensate for the variance in surface area due to shape effects.

Particle Roughness (P_(r))

Macroscopic particle roughness (defined here as 100× the diameter of theinterfacial modifier) can be defined by the circularity of the particle.It has been shown that interfacially modified surfaces of wood fiber,mineral or inorganic particulates with rough and substantiallynon-spherical shapes obtain the similar advantageous rheology andphysical property results as regularly shaped particles. The circularityor roughness of the particle can be measured by microscopic inspectionof the particles in which an automated or manual measurement ofroughness can be calculated. In such a measurement, the perimeter of arepresentative selection of the particulate is selected and the area ofthe particle cross section is also measured. The circularity of theparticle is calculated by the following formula:

Circularity = (perimeter)²/area.

Such materials such as hollow glass bubbles or solid glass beads have acircularity of 4π (for smooth spherical particles) to 50 (smoothparticles with an aspect ratio of 10). Many of wood fiber, inorganic andmineral particulate have an oblong, multi lobe, rough non-regular shapeor aspect. Such materials have a circularity of about 13 to 40, about13.6 to 40, about 13 to 35 or about 13 to 30 and obtain the improvedviscoelastic properties of the composite material. Using proper opticaland image analysis techniques the decoupling of surface roughness andaspect ratio can be determined under the appropriate magnification toquantify large scale particle roughness. The multiplier for thederivation of the particle morphology index may be adjusted for theaspect ratio of the particle.

An alternative to optical procedures consists of using a BET analysis todetermine the specific surface area of the particulate phase. Thespecific surface area captures both the macroscopic particle roughnessand particle porosity discussed below for particles of a specificparticle size and shape distribution.

Particle Porosity (P_(p))

The molecules of interfacial modifiers are quite large, on the order ofa few hundred to a few thousand molecular weight. Within a class ofcompounds, the effective diameter of the modifier molecule isproportional to the molecular weight. The predicted diameter of theNZ-12 zirconate modifier is 2260 picometer with a molecular weight of2616 g/mol. The minimum size of the modifier molecules would be about400 picometer (assuming a molecular weight of 460 g/mol). The size ofthe titanate modifiers would be slightly smaller than the correspondingzirconate for a corresponding given organophosphate structure.

Literature review of BET surface analysis reveals a large difference inparticle surface area of particles such as, for example, glass, ceramicor mineral particles (from 0.1 to >100 m²-g⁻¹). Nonporous spheres with adiameter of 1,500 microns results in a specific area of 0.017 m²-g⁻¹.Successful interfacial modification of the particulates is possible viachanges in modifier loading. It is important to note that requiredincrease in dosage is not directly proportional to the BET surfacemeasurements. The pore size penetrable by the BET probing gas issignificantly smaller (20.5 A² for krypton for example) than theinterfacial modifier. Silica sand had a pore size of 0.90 nm asdetermined by BET analysis, the interfacial modifier molecule is able tobridge the pore opening. It will be possible to successfullyinterfacially modify porous absorbents such that the particles compositerheology is improved while absorbent properties of the particulate aremaintained due to the relative size differences in the interfacialmodifier (large), pore size being bridged (small), and the size of theabsorbent molecule (nitrogen, argon, water, etc.) diffusing through theinterfacial modifier into the absorbent particulate.

The particle morphology index is defined as:

PMI = (P_(s))(P_(sh))(P_(r))(P_(p))

For large, spherical, smooth, non-porous particles the particlemorphology index=1 to 200. For small, rough, porous particles with anaspect ratio of 10, the maximum particle morphologyindex=100×10.5×100/0.1=10⁶. Certain particles with a range of particlesize (P_(s)) or diameters and aspect ratios, some roughness and porositycan range from 200 to 10⁴. Other particles with a broadened range ofsizes or diameters and aspect ratios, substantial roughness andincreased porosity can range from 2×10⁴ to 10⁶. The amount ofinterfacial modifier increases with the particle morphology index.

The result of the above particle attributes (particle size anddistribution, particle shape, and roughness) results in a specificparticle packing behavior. The relationship of these variables leads toa resultant packing fraction. Packing fraction is defined as:

P_(f) = P_(d)/d_(pync)

wherein P_(f)=packing fraction; P_(d)=packing density andd_(pync)=pyncnometer density. The relationship of these variables uponparticle packing behavior is well characterized and used within powderedmetallurgy science.

It is believed for the case of spherical particles that particle packingincreases when the size difference between large to small particlesincreases. With a size ratio of 73 parts by weight large particle: 27parts by weight small, mono-dispersed spheres with a 7:1 size ratio, thesmall particles can fit within interstitial spaces of the largeparticles resulting in a packing level of about 86 volume percent. Inpractice, it is not possible to attain mono-dispersed spheres. We havefound that increased packing is best when using particles of broadparticle size distribution with as large of a size difference betweenthem as possible. In cases like these, we have found packing percentagesapproaching 80 volume %.

For composites containing high volumetric loading of sphericalparticles, the rheological behavior of the highly packed compositesdepends on the characteristics of the contact points between theparticles and the distance between particles. When forming compositeswith polymeric volumes approximately equal to the excluded volume of theparticulate phase, inter-particle interaction dominates the behavior ofthe material. Particles contact one another and the combination ofinteracting sharp edges, soft surfaces (resulting in gouging) and thefriction between the surfaces prevent further or optimal packing.

Interfacial modifying chemistries are capable of altering the surface ofthe particulate by coordination bonding, van der Waals forces, covalentbonding, or a combination of all three. The surface of the interfaciallymodified particle behaves as a particle of the interfacial modifier. Theinterfacially modified surface of the particle and the surface of thefiber in the particulate phase is what the polymer phase of thecomposite material interacts with, not the bulk aspect or topographicalaspect of the particle or fiber itself. In this way the polymerproperties, such as viscoelastic properties like, for example, tensileelongation, melt flow, extrusion pressures, flexural properties orYoung's modulus, may be made more or less functional depending on theinterfacially modified coated particle loadings and the interfaciallymodified coated fiber particle loadings of the composite material. Theseinterfacially modifying chemistries reduce the friction betweenparticles of both the inorganic particle as well as the fiber preventinggouging among particulate surfaces and allowing for greater freedom ofmovement between the particles. In another aspect, interfaciallymodified glass particles, hollow or solid, may enter the lumen of acellulosic fiber and migrate to the interior of the cellulosic fiberstructure. This aspect may lend reinforcement to the fiber structure. Inanother aspect, a hollow glass sphere may be too large to enter thelumen. In this aspect, the glass sphere, due to the non-attachment orbonding to the polymer, may provide additional rheology properties tothe composite material (e.g. shear or viscosity) with respect totemperature and pressure. The benefits of utilizing particles in theaforementioned acceptable particle morphology index range does notbecome evident until packing to a significant proportion of the maximumpacking fraction within the polymer phase becomes a critical packinglevel. This packing fraction is a function of the multiple particledomains, such as, for example, both cellulosic and glass, in relation tothe polymer phase. This packing fraction value is typically greater thanapproximately 20, 30, or 40 volume %.

The spatial character of the inorganic particles, such as, for example,glass beads or glass bubbles, and fiber of the embodiment can be definedby the circularity of the particle and by the aspect ratio of the fiber.One surprising aspect is that a particle that departs from a smoothspherical particle shape and are non-spherical or a fiber that has asubstantial aspect ratio are efficiently packed in the compositematerial. Mineral or inorganic particulates with amorphous, rough andsubstantially non-spherical shapes obtain the same advantageous rheologyas regularly shaped particles such as glass beads and glassmicrospheres. The aspect ratio of the more regular fibers can be lessthan, 1:10, 1:5 and often less than 1:1.5. Similarly, the fibers with anaspect ratio of less than 10 or about 1:5 also obtain the benefits ofthe composites of the embodiment.

We have found that the use of the interfacial modifier obtains a closeassociation of both spherical and substantially aspherical particles atthe interfacial surface of the particles such that effective compositescan be made even with particles that depart from the ideal sphericalparticle. Many inorganic or mineral particles, depending on source andprocessing can have a narrow particle size distribution, a very regularsurface, a low aspect ratio and substantial circularity while other suchparticles can have a very amorphous non-regular geometry and surfacecharacteristic. Similarly, and surprisingly, fibers of aspect ratiosfrom about 1.5:15.0, to about 1.5:10.0 to about 1.5 to 5.0 have beenfound to interact favorably with both the spherical and non-sphericalparticles. The composite material exhibits improved properties such asmelt processing as exemplified by melt flow, a high Young's Modulus aswell as other properties. In an embodiment for structural applicationsYoung's modulus is greater than about 700 MPa or greater than about 1000MPa or greater than about 2000 MPa or greater than about 3000 MPa orgreater than about 5000 MPa or about 5000 to 2.0×10⁶ MPa. The compositematerials made using the interfacial modifier coating can obtain usefulproperties from the particle species disclosed herein.

In the composites of the embodiment, the van der Waals' forces occurbetween particles of hollow glass microspheres that act as “molecules”in the form of crystals or other mineral particle aggregates. In variousembodiments, the composite material is a composite having intermolecularforces between wood fiber, glass microsphere, non-metal, inorganic ormineral particulates that are in the range of van der Waals' strength,i.e., ranges and definitions if appropriate.

In an embodiment of the composite, the particles of hollow glassmicrospheres and wood fiber are usually much stronger and stiffer thanthe polymer phase, and give the composite its designed properties. Thepolymer phase holds the dispersed mixed particulate phase of the hollowglass microspheres and wood fiber in an orderly high-density pattern.Because the hollow glass microspheres and wood fiber are usuallydiscontinuous, the matrix also helps to transfer load among the woodfiber and hollow glass microspheres.

Processing can aid in the mixing and filling the particles of the hollowglass microsphere and wood fiber into the composite. Observations havedetermined that, unexpectedly, that at least some of the wood lumenstructure is retained throughout the processing steps with the polymerand the interfacially modified particulate such as, for example hollowglass microspheres. We can retain at least 10%, 20%, 30%, 40%, or 50%open cell structure, such as, for example, lumens, rays, or vesselswithin the wood fiber due to the interaction between the surfacesprovided by the interfacial modifier on the particle, such as aspherical hollow glass particle, and the wood fiber in the particulatephase.

If density is a functional use of the composite material, the densitymay be adjusted by inclusion of appropriate mineral particulate or metalparticulate in the dispersed mixed particulate phase. The density of thecomposite material may be less than about 10.0 g-cm³, less than about8.0 g-cm³, less than about 7.0 g-cm³, less than about 5.0 g-cm³, lessthan about 6.0 g-cm³, less than about 4.0 g-cm³, less than about 3.0g-cm³, less than 1.0 about g-cm³, less than about 0.50 g-cm³. In thematerial in general, the density can range from 0.5 to 10 g-cm³, thehigh strength low density material density ranges from 0.5 to 3.0 g-cm³.

To aid in the mixture, a surface chemical reagent, interfacial modifier,can help to overcome the forces that prevent the polymer matrix fromforming a substantially continuous phase of the composite. The tunablecomposite properties arise from the intimate association obtained by useof careful processing and manufacture. The interfacial modifier, such asorganometallic compositions, that provides a coating on the particulatepromoting the close association of polymer, particulate and fiberwithout covalent bonding between these compositional components of thecomposite material. Conceptually the particulate and fiber areimmiscible in the polymer phase because of the lack of covalent bondingbetween the compositional components of the composite material.

Differential amounts, in other words different types, quantities orvolumes, of interfacial modifier are not required for a separate coatingapplication of the particulate and fiber. Thus the steps to prepare andto coat the interfacially modified particulate and interfaciallymodified fiber may be reduced to one step. However, for specializedcomposites, differential selections of interfacial modifiers fordifferent particle applications may be desirable. In an embodiment theinterfacial modifiers may be different and the particles coated withinterfacial modifier may be the same or different. Higher amounts of theinterfacial modifier may be used to coat materials with increasedmorphology.

Hollow glass spheres (including both hollow and solid) are a usefulnon-metal or inorganic particle. These spheres are strong enough toavoid being crushed or broken during further processing of the polymericcompound, such as by high pressure spraying, kneading, extrusion orinjection molding. In many cases these spheres have densities close to,but more or less, than that of the polymeric compound into which theyare introduced in order that they distribute evenly within the compoundupon introduction and mixing. Furthermore, it is desirable that thesespheres be resistant to leaching or other chemical interaction withtheir associated polymeric compound. The method of expanding solid glassparticles into hollow glass spheres by heating is well known. See, e.g.,U.S. Pat. No. 3,365,315 herein incorporated by reference in itsentirety. Glass is ground to particulate form and then heated to causethe particles to become plastic and for gaseous material within theglass to act as a blowing agent to cause the particles to expand. Duringheating and expansion, the particles are maintained in a suspended stateeither by directing gas currents under them or allowing them to fallfreely through a heating zone. Useful glass hollow bubbles may beobtained as iM30K from 3M (St. Paul, Minn.) or as solid glass particles,2429A, 3000A or 5000A from Potters Industries, LLC (Valley Forge, Pa.)

A number of factors affect the density, size, strength, chemicaldurability and yield (the percentage by weight or volume of heatedparticles that become hollow) of hollow glass spheres. These factorsinclude the chemical composition of the glass; the sizes of theparticles fed into the furnace; the temperature and duration of heatingthe particles; and the chemical atmosphere (e.g., oxidizing or reducing)to which the particles are exposed during heating. The percentage ofsilica (SiO₂) in glass used to form hollow glass spheres may be between65 and 85 percent by weight and a weight percentage of SiO₂ below 60 to65 percent would drastically reduce the yield of the hollow spheres.

Useful hollow glass spheres having average densities of about 0.1grams-cm⁻³ to approximately 0.7 grams-cm⁻³ or about 0.125 grams-cm⁻³ toapproximately 0.6 grams-cm⁻³ are prepared by heating solid glassparticles.

For a product of hollow glass spheres having a particular desiredaverage density, there is an optimum sphere range of sizes of particlesmaking up that product which produces the maximum average strength. Acombination of a larger and a smaller hollow glass sphere wherein thereis about 0.1 to 25 wt. % of the smaller sphere and about 99.9 to about75 wt. % of larger particles can be used were the ratio of the particlesize (P_(s)) of the larger particles to the ratio of the smaller isabout 2-7:1.

Hollow glass spheres used commercially can include both solid and hollowglass spheres. All the particles heated in the furnace do not expand,and most hollow glass-sphere products are sold without separating thehollow from the solid spheres.

Useful hollow glass spheres are hollow spheres with relatively thinwalls. Such spheres typically comprise a silica-lime-or an Al-silicatehollow glass and in bulk form appear to be a white powdery particulate.The density of the hollow spherical materials tends to range from about0.1 to 0.8 g/cc and is substantially water insoluble and has an averageparticle size (P_(s)) that ranges from about 10 to 250 microns. In thecomposite material forming process, interfacially modified hollowmicrospheres are not substantially broken. In an embodiment, less than10% of the hollow glass spheres are broken during the composite formingprocess. In another embodiment, less than 1%, 2%, 3%, 4%, or 5% of thehollow glass spheres are broken during the composite forming process.

In an embodiment the fiber may be a hard or soft wood fiber, which canbe a product or product of the manufacture of lumber, other woodproducts or cellulose-based products in general. Wood fiber is anexample of cellulosed-based or cellulosic products. The soft wood fibersare relatively long, and they contain high percentages of lignin andlower percentages of hemicellulose, as compared to hard woods. Hard orsoft wood fiber particulate is chosen relative to the use of compositematerial of the embodiment. For example for structural use, hard woodfibers may be useful in the composite. However, useful cellulosic fibermay also be derived from other types of fibers, including flax, jute,hemp, cotton fibers, soft wood fibers, bamboo, rice, sugar cane, andrecycled or reclaimed fiber from newspapers, boxes, computer printouts,or the like.

Preferably, the composite comprising the composite material uses acellulosic fiber. The cellulosic fiber commonly comprises fibers havinga high aspect ratio made of cells with cellulosic cell walls. During thecomposite forming process, a fraction of the cellulosic or wood fiberstructure, such as for example, cell walls, lumens, vessel cells, andother physical cell morphology will not be compressed or disrupted. Inone embodiment, this characteristic provides the cellulosic and glassbubble composite with both structural strength and lightness. Usefularticles shaped from the composite material include dimensional lumberreplacements, decorative building siding, structural building panels,roofing panels, flooring panels, foundation panels, fencing, deckrailings, automobile panels, acoustic and heat insulation panels.Polymer is not introduced into the interior void volume of the cellsunder conditions of high temperature and pressure. In other embodimentsthe fiber may be hard wood fiber but soft wood fiber is also useful. Thecomposite can be formed into any useful form such as powder pellet ormember. The composite and members of the composite comprises fiber butcan also contain other forms of fiber such as fabric in the form ofwoven or non-woven fabric. Such fabric can be added as fabric portionswith a surface area of greater than 5 mm², can be coextruded ascoextensive fabric within the extrusion or can be added to the compositeafter extrusion or other formation.

In compositions of the embodiments, the composite materials maintainboth an effective composite formation of loadings of greater than 20vol. % but also maintain substantial viscoelasticity and polymercharacteristics at fiber and particulate loadings that range greaterthan 25 vol. %, greater than 35 vol. %, greater than 40 vol. % and canrange from about 40 vol. % to as much as 95 vol. %. In these ranges ofparticulate loading, the composites in the application maintain theviscoelastic properties of the polymer in the polymer phase. As suchwithin these polymer loadings, useful elongation at break wherein theelongations can be in excess of 5%, in excess of 10%, in excess of 20%,and can range from about 20 to 500% elongation at break. Further, thetensile yield point can substantially exceed the prior art materials andcan range from about 5 to 10% elongation.

In compositions of the embodiments, the composite materials maintainboth an effective composite formation of loadings of greater than 20vol. % but also maintain substantial flexural properties characteristicsat fiber and particulate loadings that range greater than 25 vol. %,greater than 35 vol. %, greater than 40 vol. % and may range from about40 vol. % to as much as 80 vol. %. In these ranges of particulateloading, the composites in the application maintain flexural propertiesof greater than 700, 800, 900, 1000, 1200, 1400, 1600, 1800, 2000, 2500,2700, 2900, 3200, 3300, 3500, 3700, 3900, 4100, 4300, 4500, or 4700 MPaas measured by ASTM D790 with appropriate modifications. It is difficultto predict the explicit properties due to the variable of polymer typeor blend and its effect on the relative to modulus or flexural stress.In embodiments, Melt Flow Analysis (MFA) of the composite material, asmeasured with a Model 50 Mini-Jector from Miniature Plastics Molding(MPM) (Solon, Ohio), will exhibit improved melt flow in comparison tocomposite materials made with particulate that is not coated with aninterfacial modifier. By way of example, the MFA for a compositematerial in accordance with embodiments herein will be 10%, 20%, 30%,40%, 50%, 60%, 70%, 80%, or 90% less than otherwise identicalcompositions made with particulate that is not coated with theinterfacial modifier. Similar beneficial properties for the compositematerial may be seen in extrusion pressure and flexural properties.

Typically, the composite materials herein are manufactured using meltprocessing and are also utilized in product formation using meltprocessing. In an embodiment, a thermoplastic polymer, is combined withthe particulate portion and the cellulosic fiber portion, such as, forexample, wood fiber, and processed until the material attains compositeproperties such as, for example, a uniform density (if density is thecharacteristic used as a determinant). Once the material attains asufficient property, such as, for example, density, the material can beextruded into a product or into a raw material in the form of a pellet,chip, wafer, preform, or other easily processed material usingconventional processing techniques. Representative physical propertiesof the composite material uniformly coated with an interfacial modifierare summarized below.

The range of values of the properties depends primarily on the portionsof the dispersed mixed particulate within the polymer phase and can beas follows:

Polymer/Wood Fiber/ Testing Property Glass Bubbles Composite ProtocolSpecific Gravity 0.87-1.17-1.47 g/cc Puck density or Gas pycnometry asdescribed Flame Resistance 0 UL 94 Water Vapor 0.22-1.22-2.22% UptakeLiquid Water 0.75-1.75-2.75% ASTM Uptake D570 Impact Strength8-13.0-j/cm ASTM D5420 Flexural Modulus 2500-2900-3300 MPa ASTM D790Flexural Strength 18-23-28 Pa ASTM at Yield D790 Flexural Strength35-45-55 Pa ASTM at Break D790 Tensile Modulus 500-700-900 MPa ASTM D638Tensile Strength 12-15-18 MPa ASTM at Yield D638 Tensile Strength12-17-22 MPa ASTM at Break D638 k-value 0.10-0.31 W/m-° k Lee’s Disk(thermal Apparatus conductivity)

In the manufacture of useful products with the composites of theembodiment, the manufactured shaped article made from the compositematerial can be obtained in appropriate amounts, subjected to heat andpressure, typically in extruder or injection molding equipment and thenformed into an appropriate shape in the appropriate physicalconfiguration.

In the appropriate product design, during composite manufacture orduring product manufacture, a pigment or other dye material can be addedto the processing equipment. One advantage of this material is that aninorganic dye or pigment can be co-processed resulting in a materialthat needs no exterior painting or coating to obtain an attractive,functional, or decorative appearance. The pigments can be included inthe polymer blend, can be uniformly distributed throughout the materialand can result in a surface that cannot chip, scar or lose itsdecorative appearance. One particularly important pigment materialcomprises titanium dioxide (TiO₂). This material is non-toxic, is abright white particulate that can be easily combined with eithernon-metal, inorganic or mineral particulates and/or polymer compositesto enhance the novel characteristics of the composite material and toprovide a white hue to the ultimate composite material.

In another embodiment, the feedstock for additive manufacturing systems(AM) is made from the glass and wood polymer composite material and isfed through extrusion-based AM systems for building 3D models. Additivemanufacturing, or 3D printing, is a manufacturing process for making athree-dimensional solid object of virtually any shape from a digitalmodel. 3D printing is achieved using an additive process, wheresuccessive layers of material are laid down in different shapes. 3Dprinting is considered distinct from traditional machining techniques,which rely on the removal of material by methods such as cutting ordrilling (subtractive processes). A materials printer usually performsAM system processes using digital technology. The technology is used forboth prototyping and distributed manufacturing with applications inarchitecture, construction (AEC), industrial design, automotive,aerospace, military, engineering, civil engineering, dental and medicalindustries, biotech (human tissue replacement), fashion, footwear,jewelry, eyewear, education, geographic information systems, food, andmany other fields.

AM system processes renders virtual blueprints from computer aideddesign (CAD) and “slices” them into digital cross-sections for themachine to successively use as a guideline for printing. Depending onthe machine used, material or a binding material is deposited on thebuild bed or platform until material/binder layering is complete and thefinal 3D model has been “printed.” It is a WYSIWYG (watch you see iswhat you get) process where the virtual model and the physical model arealmost identical.

To perform a print, the machine reads the design from a computer fileand lays down successive layers of the composite material to build themodel from a series of cross sections. In the embodiments of thisapplication, the viscoelastic composite materials comprisinginterfacially coated wood fiber, glass particle and optionally anotherparticle such as ceramic, inorganic minerals, metal particles andspheres are especially useful in AM system processes. These layers,which correspond to the virtual cross sections from the CAD model, arejoined or automatically fused to create the final shape. The primaryadvantage of this technique is its ability to create almost any shape orgeometric feature in three-dimensional space, or xyz-space. AM systemresolution describes layer thickness and X-Y resolution in dpi (dots perinch), or micrometers. Typical layer thickness is around 16 to 100micrometers (μm). Construction of a model with contemporary methods cantake anywhere from hours to days, depending on the method used and thesize and complexity of the model. Additive manufacturing systems cantypically reduce this time to a few hours, although it varies widelydepending on the type of machine used and the size and number of modelsbeing produced simultaneously.

Such systems are commercially available from Stratasys, Inc. EdenPrairie Minn., as well as from other larger format additive manufacturessuch as Siemens or General Electric. After sintering, the object orshape can be worked, heated, polished, painted or otherwise formed intonew finished shapes or structures.

The filament, wire, or feedstock, is a compositional component thatfeeds through the additive manufacturing (printer) system by an extruderscheme and builds a shaped article in layers deposited from thefilament. For example the filament or wire is urged into the extrusionzone (hot end) by an extrusion stepper motor attached to an extrusionwheel. The extruder wheel pushes the required volume of the filament tothe extrusion zone. Depending on the printer system, the filament may becircular or round in cross-section. In an embodiment, the diameter of afilament may range from 1.20 to 3.8 mm, 1.20 to 3.00 mm, 1.50 to 2.50mm, 1.50 to 1.80 mm, or 1.50 to 1.75 mm in a circular or round crosssection. The filament diameter tolerance should be within a +/−0.03 mmtolerance. Inconsistent or irregular filament diameter may lead to manyproblems. In one example, inconsistent filament diameters lead tovariable volume and layer deposition due an improper volume of filamentbeing heated in the extrusion zone. In other embodiments, square orpyramidal cross-sectional shapes are provided for the filaments usefulfor printer systems. Other cross-sectional shapes of the filament arealso possible.

The filament is fed by the extrusion stepper motor into the extrusionzone. In an embodiment the feed rates may be 10 to 500 mm/sec, 10 to 400mm/sec, 100 to 400 mm/sec, or 200 to 300 mm/sec, in the extrusion zonethe filament is heated. In an embodiment the temperature of the filamentmay be 150 C to 300 C, 150 C to 280 C, 170 C to 300 C, or 170 C to 250C.

In an embodiment, in weight percentages, a filament useful in additivemanufacturing can have the proportions of composite materials asdiscussed herein. As a specific non-limiting example, such a filamentmay comprise:

1) 0.05 to 6.0 wt. % of interfacial modifier,

2) 10 to 70 wt. % of polymer,

3) 20 to 90 wt. % of a mixed dispersed particulate wherein the mixedparticulate comprises

-   -   i) 20 to 80 wt. % of a wood fiber particulate, and    -   ii) 80 to 20 wt. % of a inorganic particle.

In an embodiment in volume percentages, as a non-limiting example, afilament useful in additive manufacturing may comprise:

1) 0.05 to 6.0 vol. % of interfacial modifier,

2) 10 to 70 vol. % of polymer,

3) 20 to 90 volume % of a mixed dispersed particulate wherein the mixedparticulate comprises:

-   -   i) 20 to 80 vol. % of a wood fiber particulate, and    -   ii) 80 to 20 vol. % of a inorganic particle.

We have further found that a blend of two, three or more non-metal,inorganic or minerals in particulate form in addition to wood fiber oralternative fiber material, such as glass, boron, carbon, aramid, metal,cellulosic, polyester, nylon can obtain important composite propertiesfrom all of the components in a polymer composite structure. Suchcomposites each can have unique or special properties. These compositeprocesses and materials have the unique capacity and property such thatthe composite material acts as a blended composite that could not, dueto melting point and other processing difficulties, be made into a blendof properties without the methods of the making the composite material.

Polymers

A large variety of polymer materials can be used in the compositematerials. For the purpose of this application, a polymer is a generalterm covering either a thermoset or a thermoplastic. We have found thatuseful polymer materials include both condensation polymeric materialsand addition or vinyl polymeric materials. Included are both vinyl andcondensation polymers, and polymeric alloys thereof. The polymer has adensity of at least 0.85 g-cm⁻³, however, polymers having a density ofgreater than 0.96 are useful to enhance overall product density. Adensity is often up to 1.7 or up to 2 g-cm⁻³ or up to 1.90 g-cm⁻³ or 0.9to 1.90 g-cm⁻³ or can be about 1.5 to 1.95 g-cm⁻³. The polymer phase maybe present in the composite material in about 10.0 to 70.0 wt. %, inabout 10.0 to 60.0 wt. % or in about 10.0 to 50.0% wt. %. The polymerphase in the composite material may be a continuous polymer phase as itis known in the polymer technology art.

Vinyl polymers include polyethylene, polypropylene, polybutylene,acrylonitrile-butadiene-styrene (ABS), polybutylene copolymers,polyacetyl resins, polyacrylic resins, homopolymers or copolymerscomprising vinyl chloride, vinylidene chloride, fluorocarbon copolymers,etc. Condensation polymers include nylon, phenoxy resins, polyarylethersuch as polyphenylether, polyphenylsulfide materials; polycarbonatematerials, chlorinated polyether resins, polyethersulfone resins,polyphenylene oxide resins, polysulfone resins, polyimide resins,thermoplastic urethane elastomers and many other resin materials.

Condensation polymers that can be include polyamides, polyamide-imidepolymers, polyarylsulfones, polycarbonate, poly (lactic acid) orpolylactide (PLA) polybutylene terephthalate, polybutylenenaphthalate,polyetherimides, polyethersulfones, polyethylene terephthalate,thermoplastic polyamides, polyphenylene ether blends, polyphenylenesulfide, polysulfones, thermoplastic polyurethanes and others. Usefulcondensation engineering polymers include polycarbonate materials,polyphenyleneoxide materials, and polyester materials includingpolyethylene terephthalate, polybutylene terephthalate, polyethylenenaphthalate and polybutylenenaphthalate materials.

Polycarbonate engineering polymers are high performance, amorphousengineering thermoplastics having high impact strength, clarity, heatresistance and dimensional stability. Polycarbonates are generallyclassified as a polyester or carbonic acid with organic hydroxycompounds. The common polycarbonates are based on phenol A as a hydroxylcompound copolymerized with carbonic acid. Polycarbonates can often beused as a versatile blending material as a component with othercommercial polymers in the manufacture of alloys. Polycarbonates can becombined with polyethylene terephthalateacrylonitrile-butadiene-styrene, styrene maleic anhydride and others.Useful alloys comprise a styrene copolymer and a polycarbonate. Usefulpolycarbonate materials should have a melt index between 0.5 and 7,preferably between 1 and 5 g-10 min⁻¹.

A variety of polyester condensation polymer materials includingpolyethylene terephthalate, polybutylene terephthalate, polyethylenenaphthalate, polybutylenenaphthalate, etc. can be useful. Polyethyleneterephthalate and polybutylene terephthalate are high performancecondensation polymer materials. Polyethylene naphthalate andpolybutylenenaphthalate materials can be made by copolymerizing as aboveusing as an acid source, a naphthalene dicarboxylic acid. Thenaphthalate thermoplastics have a higher Tg and higher stability at hightemperature compared to the terephthalate materials. However, thesepolyester materials are useful in the composite materials. Suchmaterials have a useful molecular weight characterized by melt flowproperties. Useful polyester materials have a viscosity at 265° C. ofabout 500-2000 cP, preferably about 800-1300 cP.

Polyphenylene oxide materials are engineering thermoplastics that areuseful at temperature ranges as high as 330° C. Polyphenylene oxide hasexcellent mechanical properties, dimensional stability, and dielectriccharacteristics. Commonly, phenylene oxides are manufactured and sold aspolymer alloys or blends when combined with other polymers or fiber.Polyphenylene oxide typically comprises a homopolymer of2,6-dimethyl-1-phenol. The polymer commonly known aspoly(oxy-(2,6-dimethyl-1,4-phenylene)). Polyphenylene is often used asan alloy or blend with a polyamide, typically nylon 6-6, alloys withpolystyrene or high impact styrene and others. A melt index (ASTM 1238)for the polyphenylene oxide material can range from about 1 to 20,preferably about 5 to 10 g/10 min. The melt viscosity is about 1000 cPat 265° C.

Another class of thermoplastic includes styrenic copolymers. The termstyrenic copolymer indicates that styrene is copolymerized with a secondvinyl monomer resulting in a vinyl polymer. Such materials contain atleast a 5 mol-% styrene and the balance being 1 or more other vinylmonomers. An important class of these materials is styrene acrylonitrile(SAN) polymers. SAN polymers are random amorphous linear copolymersproduced by copolymerizing styrene acrylonitrile and optionally othermonomers. Emulsion, suspension and continuous mass polymerizationtechniques have been used. SAN copolymers possess transparency,excellent thermal properties, good chemical resistance and hardness.These polymers are also characterized by their rigidity, dimensionalstability and load bearing capability. Olefin modified SAN's (OSApolymer materials) and acrylic styrene acrylonitriles (ASA polymermaterials) are known. These materials are somewhat softer thanunmodified SAN's and are ductile, opaque, two phased terpolymers thathave surprisingly improved weather-ability.

ASA polymers are random amorphous terpolymers produced either by masscopolymerization or by graft copolymerization. These materials can alsobe blended or alloyed with a variety of other polymers includingpolyvinyl chloride, polycarbonate, polymethyl methacrylate and others.An important class of styrene copolymers includes theacrylonitrile-butadiene-styrene monomers (ABS). These polymers are veryversatile family of engineering thermoplastics produced bycopolymerizing the three monomers. Each monomer provides an importantproperty to the final terpolymer material. The final material hasexcellent heat resistance, chemical resistance and surface hardnesscombined with processability, rigidity and strength. The polymers arealso tough and impact resistant. The styrene copolymer family ofpolymers have a melt index that ranges from about 0.5 to 25, preferablyabout 0.5 to 20.

An important class of engineering polymers that can be used in thecomposite material include acrylic polymers. Acrylics comprise a broadarray of polymers and copolymers in which the major monomericconstituents are an ester acrylate or methacrylate. These polymers areoften provided in the form of hard, clear sheet or pellets. Usefulacrylic polymer materials have a melt index of about 0.5 to 50,preferably about 1 to 30 g/10 min.

Vinyl polymer polymers include a acrylonitrile; polymer of alpha-olefinssuch as ethylene, propylene, etc.; chlorinated monomers such as vinylchloride, vinylidene dichloride, acrylate monomers such as acrylic acid,methylacrylate, methylmethacrylate, acrylamide, hydroxyethyl acrylate,and others; styrenic monomers such as styrene, alphamethyl styrene,vinyl toluene, etc.; vinyl acetate; and other commonly availableethylenically unsaturated monomer compositions.

Thermoplastics include polyvinylchloride, polyphenylene sulfite, acrylichomopolymers, maleic anhydride containing polymers, acrylic materials,vinyl acetate polymers, diene containing copolymers such as1,3-butadiene, 1,4-pentadiene, halogen or chlorosulfonyl modifiedpolymers or other polymers and are useful within the composite materialof the invention. Condensation polymeric thermoplastics can be usedincluding polyamides, polyesters, polycarbonates, polysulfones andsimilar polymer materials by reacting end groups with silanes havingaminoalkyl, chloroalkyl, isocyanato or similar functional groups.

Polyvinyl chloride is a common commodity thermoplastic polymer. Vinylchloride monomer is made from a variety of different processes such asthe reaction of acetylene and hydrogen chloride and the directchlorination of ethylene. Polyvinyl chloride is typically manufacturedby the free radical polymerization of vinyl chloride resulting in auseful thermoplastic polymer. After polymerization, polyvinyl chlorideis commonly combined with thermal stabilizers, lubricants, plasticizers,organic and inorganic pigments, fillers, biocides, processing aids,flame retardants, and other commonly available additive materials. Auseful polyvinyl chloride in an embodiment is 87180 from PolyOne (AvonLake, Ohio)

Polyvinyl chloride can also be combined with other vinyl monomers in themanufacture of polyvinyl chloride copolymers. Such copolymers can belinear copolymers, branched copolymers, graft copolymers, randomcopolymers, regular repeating copolymers, block copolymers, etc.Monomers that can be combined with vinyl chloride to form vinyl chloridecopolymers include an acrylonitrile; alpha-olefins such as ethylene,propylene, etc.; chlorinated monomers such as vinylidene dichloride;acrylate monomers such as acrylic acid, methylacrylate,methylmethacrylate, acrylamide, hydroxyethyl acrylate, and others;styrenic monomers such as styrene, alphamethyl styrene, vinyl toluene,etc.; vinyl acetate; and other commonly available ethylenicallyunsaturated monomer compositions. Such monomers can be used in an amountof up to about 50 mol-%, the balance being vinyl chloride. In anembodiment the composite comprises or about 20.0 wt. % to 50.0 wt. % orabout 20.0 Wt. % to 60.0 wt. % or about 20.0 wt. % to 70.0 wt. % orabout 20.0 Wt. % to 80.0 wt. % or about 20.0 wt. % to 90.0 wt. %polyvinyl chloride,

Polymer blends or polymer alloys can be useful in manufacturing thepellet or linear extrudate of the composite material. Such alloystypically comprise two miscible polymers blended to form a uniformcomposition. A polymer alloy at equilibrium comprises a mixture of twoamorphous polymers existing as a single phase of intimately mixedsegments of the two macro molecular components. Miscible amorphouspolymers form glasses upon sufficient cooling and a homogeneous ormiscible polymer blend exhibits a single, composition dependent glasstransition temperature (Tg). Immiscible or non-alloyed blend of polymerstypically displays two or more glass transition temperatures associatedwith immiscible polymer phases. In the simplest cases, the properties ofpolymer alloys reflect a composition weighted average of propertiespossessed by the components. In general, however, the propertydependence on composition varies in a complex way with a particularproperty, the nature of the components (glassy, rubbery orsemi-crystalline), the thermodynamic state of the blend, and itsmechanical state whether molecules and phases are oriented.

The primary requirement for the substantially thermoplastic engineeringpolymer material is that it retains sufficient thermoplastic propertiessuch as viscosity and stability, to permit melt blending with aparticulate, permit formation of linear extrudate pellets, and to permitthe composition material or pellet to be extruded or injection molded ina thermoplastic process forming the useful product. Engineering polymerand polymer alloys are available from a number of manufacturersincluding Dyneon LLC, B.F. Goodrich, G.E., Dow, and duPont.

Phenolic polymers can also be used in the manufacture of the structuralmembers of the composite material. Phenolic polymers typically comprisea phenol-formaldehyde polymer. Such polymers are inherently fireresistant, heat resistant and are low in cost.

The fluorocarbon polymers useful in the composite material areperflourinated and partially fluorinated polymers made with monomerscontaining one or more atoms of fluorine, or copolymers of two or moreof such monomers. Common examples of fluorinated monomers useful inthese polymers or copolymers include tetrafluoroethylene (TFE),hexafluoropropylene(HFP), vinylidene fluoride (VDF), perfluoroalkylvinylethers such as perfluoro-(n-propyl-vinyl) ether (PPVE) orperfluoromethylvinylether (PMVE). Other copolymerizableolefinicmonomers, including non-fluorinated monomers, may also be present.

Particularly useful materials for the fluorocarbon polymers areTFE-HFP-VDF terpolymers (melting temperature of about 100 to 260° C.;melt flow index at 265° C. under a 5 kg load is about 1-30 g-10 min⁻¹.),hexafluoropropylene-tetrafluoroethylene-ethylene (HTE) terpolymers(melting temperature about 150 to 280° C.; melt flow index at 297° C.under a 5 kg load of about 1-30 g-10 min⁻¹.),ethylene-tetrafluoroethylene (ETFE) copolymers (melting temperatureabout 250 to 275° C.; melt flow index at 297° C. under a 5 kg load ofabout 1-30 g-10 min⁻¹.), hexafluoropropylene-tetrafluoroethylene (FEP)copolymers (melting temperature about 250 to 275° C.; melt flow index at372° C. under a 5 kg load of about 1-30 g-10 min⁻¹.), andtetrafluoroethylene-perfluoro(alkoxy alkane) (PFA) copolymers (meltingtemperature about 300 to 320° C.; melt flow index at 372° C. under a 5kg load of about 1-30 g-10 min⁻¹.). Each of these fluoropolymers iscommercially available from Dyneon LLC, Oakdale, Minn. The TFE-HFP-VDFterpolymers are sold under the designation “THV”.

Also useful are vinylidene fluoride polymers primarily made up ofmonomers of vinylidene fluoride, including both homo polymers andcopolymers. Such copolymers include those containing at least 50 molepercent of vinylidene fluoride copolymerized with at least one comonomerselected from the group of tetrafluoroethylene, trifluoroethylene,chlorotrifluoroethylene, hexafluoropropene, vinyl fluoride,pentafluoropropene, and any other monomer that readily copolymerizeswith vinylidene fluoride. These materials are further described in U.S.Pat. No. 4,569,978 (Barber) incorporated herein by reference. Suchmaterials are commercially available under the KYNAR trademark fromArkema Group located in King of Prussia, Pa. or under the DYNEONtrademark from Dyneon LLC of Oakdale, Minn.

Fluorocarbon elastomer materials can also be used in the compositematerials. Fluorocarbon elastomers contain VF₂ and HFP monomers andoptionally TFE and have a density greater than 1.8 g-cm⁻³. Thesepolymers exhibit good resistance to most oils, chemicals, solvents, andhalogenated hydrocarbons, and excellent resistance to ozone, oxygen, andweathering. Their useful application temperature range is −40° C. to300° C. Fluorocarbon elastomer examples include those described indetail in Lentz, U.S. Pat. No. 4,257,699, as well as those described inEddy et al., U.S. Pat. No. 5,017,432 and Ferguson et al., U.S. Pat. No.5,061,965. The disclosures of each of these patents are totallyincorporated herein by reference.

Latex fluorocarbon polymers are available in the form of the polymerscomprising the PFA, FEP, ETFE, HTE, THV and PVDF monomers. Fluorinatedpoly(meth)acrylates can generally be prepared by free radicalpolymerization either neat or in solvent, using radical initiators wellknown to those skilled in the art. Other monomers which can becopolymerized with these fluorinated (meth)acrylate monomers includealkyl (meth)acrylates, substituted alkyl (meth)acrylates, (meth)acrylicacid, (meth)acrylamides, styrenes, vinyl halides, and vinyl esters. Thefluorocarbon polymers can comprise polar constituents. Such polar groupsor polar group containing monomers may be anionic, nonionic, cationic,or amphoteric. The latex fluorocarbon polymers described herein aretypically aqueous dispersed solids but solvent materials can be used.The fluorocarbon polymer can combined with various solvents to formemulsion, solution or dispersion in a liquid form. Dispersions offluoropolymers can be prepared using conventional emulsionpolymerization techniques, such as described in U.S. Pat. Nos.4,418,186; 5,214,106; 5,639,838; 5,696,216 or Modern Fluoropolymers,Edited by John Scheirs, 1997 (particularly pp. 71-101 and 597-614) aswell as assignees' copending patent application Ser. No. 01/03195, filedJan. 31, 2001.

The liquid forms can be further diluted in order to deliver the desiredconcentration. Although aqueous emulsions, solutions, and dispersionsare useful, up to about 50% of a cosolvent such as methanol,isopropanol, or methyl perfluorobutyl ether may be added. Preferably,the aqueous emulsions, solutions, and dispersions comprise less thanabout 30% cosolvent, more preferably less than about 10% cosolvent, andpreferably the aqueous emulsions, solutions, and dispersions aresubstantially free of cosolvent.

Interfacial Modifier

Interfacial modifiers provide the close association of the particle withthe polymer. Interfacial modifiers used in the non-reactive ornon-crosslinking application to provide non-reactive surfaces onparticulate fall into broad categories including, for example, stearicacid derivatives, titanate compounds, zirconate compounds, phosphonatecompounds, aluminate compounds.

Aluminates, phosphonates, titanates and zirconates useful contain fromabout 1 to about 3 ligands comprising hydrocarbyl phosphate estersand/or hydrocarbylsulfonate esters and about 1 to 3 hydrocarbyl ligandswhich may further contain unsaturation and heteroatoms such as oxygen,nitrogen and sulfur. Preferably the titanates and zirconates containfrom about 2 to about 3 ligands comprising hydrocarbyl phosphate estersand/or hydrocarbyl sulfonate esters, preferably 3 of such ligands andabout 1 to 2 hydrocarbyl ligands, preferably 1 hydrocarbyl ligand.

The choice of interfacial modifiers is dictated by fiber, particulate,polymer, and application. The wood fiber and particle are coated even ifhaving substantial morphology. For example, the maximum density of acomposite is a function of the densities of the components and thevolume fractions of each. Higher density composites are achieved bymaximizing the per unit volume of the components with the highestdensities. When forming composites with polymeric volumes approximatelyequal to the excluded volume of the fiber and particulates,inter-particle-fiber interaction dominates the behavior of the material.Particles and fibers contact one another via opposing surfaces and thecombination of interacting sharp edges, soft surfaces and the frictionbetween the surfaces prevent further or optimal packing. Therefore,maximizing properties of the particles is a function of softness ofsurface, hardness of edges, point size of point (sharpness), surfacefriction force and pressure on the material, circularity, aspect ratioand the usual, shape size distribution. Because of thisinter-particle-fiber friction, the forming pressure will decreaseexponentially with distance from the applied force.

Interfacially modifying chemistries are capable of modifying thesurfaces of the fibers and particles by coordination bonding, van derWaals forces, covalent bonding, or a combination of all three. Thesurface of the particle and fiber behaves as a particle or fiber of theinterfacial modifier. These organic materials of the interfacialmodifiers reduce the friction between particles and fibers preventinggouging and allowing for greater freedom of movement between particlesand fibers. These phenomena allow the applied shaping force to reachdeeper into the form resulting in a more uniform, and in many instancesa lower, pressure gradient present during extrusion or injectionmolding.

Useful titanates and zirconates include isopropyltri(dioctyl)pyrophosphato titanate (available from Kenrich Chemicalsunder the designation KR38S), neopentyl(diallyl)oxy,tri(dodecyl)benzene-sulfonyl titanate (available from Kenrich Chemicalsunder the trademark and designation LICA 09), neopentyl(diallyl)oxy,trioctyl phosphato titanate (available from Kenrich Chemicals under thetrademark and designation LICA 12), neopentyl(diallyl)oxy,tri(dodecyl)benzene-sulfonyl zirconate (available from Kenrich Chemicalsunder the designation NZ 09), neopentyl(diallyl)oxy,tri(dioctyl)phosphato zirconate (available from Kenrich Chemicals underthe designation NZ 12), and neopentyl(diallyl)oxy,tri(dioctyl)pyro-phosphato zirconate (available from Kenrich Chemicalsunder the designation NZ 38). A useful titanate istri(dodecyl)benzene-sulfonyl titanate (available from Kenrich Chemicalsunder the designation LICA 09). The interfacial modifiers modify theparticulate in the composite material with the formation of a layer onthe surface of the particle reducing the intermolecular forces,improving the tendency of the polymer to mix with the particle,improving mixing and packing of particles and resulting in compositeviscoelastic properties. In one embodiment density is minimized for thecomposite material. Other composite properties may be tuned as disclosedin the aforementioned table.

Thermosetting polymers can be used in an uncured form to make thecomposites with the interfacial modifiers. Once the composite is formedthe reactive materials can chemically bond the polymer phase if athermoset polymer is selected. The reactive groups in the thermoset caninclude methacrylyl, styryl, or other unsaturated or organic materials.

Manufacture of Pellet

The manufacture of the particulate and fiber composite materials dependson good manufacturing technique. Often the particulate and fiber isinitially treated to ensure uniform particulate coating.

The interfacial modifier can also be added to particles and fibers witha coating application in bulk blending operations using high intensityblenders, such as, for example, Littleford or Henschel blenders.Alternatively, twin cone mixers can be followed by drying or directaddition to a screw compounding device. Interfacial modifiers may alsobe reacted with the particulate and fiber in a solvent such as,isopropyl alcohol, toluene, tetrahydrofuran, mineral spirits or othersuch known solvents.

The particulate and fiber can be interfacially combined into the polymerphase depending on the nature of the polymer phase, the fiber, theparticulate surface chemistry and any pigment process aid or additivepresent in the composite material. In general, the mechanism used toassociate the particulate and fiber to the polymer include solvation,chelation, coordination bonding (ligand formation), etc. Typically,however, covalent bonds, linking or coupling the fiber, the particle,interfacial modifier, and the polymer are not formed. Titanate,phosphonate or zirconate agents can be used. Such agents have thefollowing formula:

(RO)_(m)—Ti—(O—X—R′—Y)_(n)

(RO)_(m)—Zr—(O—X—R′—Y)_(n)

(RO)_(m)—P—(O—X—R′—Y)_(n)

wherein R and R′ are independently a hydrocarbyl, C1-C12 alkyl group ora C7-20 alkyl or alkaryl group wherein the alkyl or alkaryl groups mayoptionally contain one or more oxygen atoms or unsaturation; X issulfate or phosphate; Y is H or any common substituent for alkyl or arylgroups; m and n are 1 to 3. Titanates provide antioxidant properties andcan modify or control cure chemistry. Zirconate provides excellent bondstrength but maximizes curing, reduces formation of off color informulated thermoplastic materials. A useful zirconate material isneopentyl(diallyl)oxy-tri(dioctyl)phosphato-zirconate.

The composite materials having the desired physical properties can bemanufactured as follows. In an embodiment, the surface of theparticulate and fiber is initially prepared, the interfacial modifier iscoated, and the resulting product is isolated and then combined with thecontinuous polymer phase to affect an interfacial association betweenthe particulate, fiber and the polymer. Once the composite material isprepared, it is then formed into the desired shape of the end usematerial. Solution processing is an alternative that provides solventrecovery during materials processing.

The materials can also be dry-blended without solvent. Blending systemssuch as ribbon blenders obtained from Drais Systems, high density driveblenders available from Littleford Brothers and Henschel are possible.Further melt blending using Banberry, veferralle single screw or twinscrew compounders is also useful. When the materials are processed as aplastisol or organosol with solvent, liquid ingredients are generallycharged to a processing unit first, followed by polymer, particulate andfiber and rapid agitation. Once all the materials are added a vacuum canbe applied to remove residual air and solvent, and mixing is continueduntil the composite material of the product is uniform.

Dry blending is generally preferred due to advantages in cost. Howevercertain embodiments can be compositionally unstable due to differencesin wood fiber and particle size. In dry blending processes, thecomposite can be made by first introducing the polymer, combining thepolymer stabilizers, if necessary, at a temperature from about ambientto about 60° C. with the polymer, blending a particulate and fiber withthe stabilized polymer, blending other process aids, interfacialmodifier, colorants, indicators or lubricants followed by mixing in hotmix, transfer to storage, packaging or end use manufacture.

Interfacially modified fiber and particulate materials can be made withsolvent techniques that use an effective amount of solvent to initiateformation of a composite. Care should be taken to maximize lumenretention of the wood fiber. During the steps of particle preparation,compounding and extrusion, it is easy to damage the fibers. Wheninterfacial treatment is substantially complete, the solvent can bestripped. Such solvent processes are conducted as follows:

-   -   1) Solvating the interfacial modifier or polymer or both;    -   2) Mixing the particulate and fiber into a bulk phase or polymer        master batch: and    -   3) Devolatilizing the composition in the presence of heat &        vacuum above the Tg of the polymer.

When compounding with twin screw compounders or extruders, a usefulprocess can be used involving twin screw compounding as follows.

1. Add particulate and fiber and raise temperature to remove surfacewater.

2. Add interfacial modifier and fiber to twin screw when at temperature.

3. Disperse/distribute surface chemical treatment on fiber andparticulate.

4. Maintain temperature to completion.

5. Vent by-products.

6. Add polymer binder.

7. Compress/melt polymer binder.

8. Disperse/distribute polymer binder in particulate and fiber.

9. Combine modified particulate and fiber with polymer binder.

10. Vacuum degas remaining products.

11. Compress resulting composite.

12. Form desired shape, pellet, lineal, tube, injection mold article,etc. through a die or post-manufacturing step.

Alternatively in formulations containing small volumes of continuousphase:

1. Add polymer binder.

2. Add interfacial modifier to twin screw when polymer binder is attemperature.

3. Disperse/distribute interfacial modifier in polymer binder.

4. Add filler and disperse/distribute particulate and fiber.

5. Raise temperature

6. Maintain temperature to completion.

7. Compress resulting composite.

8. Form desired shape, pellet, lineal, tube, injection mold article,etc. through a die or post-manufacturing step.

In an embodiment of the pellet compositions the particulate comprisingwood fiber and hollow microsphere particulate comprise at least about 40vol. %, at least about 45 vol. %, or at least about 50 vol. %. Thepellet can have a variety of cross-sectional shapes includingtriangular, square, rectangular, oval, etc.

A useful pellet is a cylinder, the preferred radius of the cylinder isat least 1.5 mm with a length of at least 1 mm. Preferably, the pellethas a radius of 1 to 5 mm and a length of 1 to 10 mm. In an embodiment,the cylinder has a radius of 2.3 to 2.6 mm, a length of 2.4 to 4.7 mm,and a bulk density of about 0.2 to about 0.8 g-cm⁻³.

After the pellets are formed, the panels or other objects are preferablyprofile extruded in the specific cross-sectional shape desired. However,it is also possible for the panels to be molded, vacuum formed, bent orroll-formed from sheet material. The panels can be fabricated inpre-specified lengths for the particular job application desired, or canbe formed in standard lengths and cut to size at the building site.

Control of moisture in the polymer, particle, and fiber composite isimportant to obtaining consistent, high-quality composite material anddimensional stability. Removal of a substantial proportion of the waterin the fiber is required in order to obtain an optimal pellet forprocessing. Preferably, water is controlled to a level of less thanabout 12 wt.-%, of less than about 10 wt.-%, of less than about 8 wt.-%,of less than about 5 wt.-% in the pellet, based on the pellet weight, ifprocessing conditions provide that vented extrusion equipment can drythe material prior to the final formation of any shaped article.

In an embodiment, the composite material may be used for making astructural composite useful for making panels for siding, flooring,roofing, decking, railings panels for building huts or temporarybuildings, structural members or unit module, The composite material tomake the structural material comprises polyvinyl chloride, interfaciallymodified particulate and interfacially modified wood fiber, wherein thespecific gravity of the pellet used to make the structural material isabout 1.17 gram per cubic cm. for reasons of improved thermalproperties, structural properties, modulus, compression strength, etc.

The coefficient of thermal expansion of the polymer-fiber-particulatecomposite material is a reasonable compromise between the longitudinalcoefficient of thermal expansion of PVC, which is typically about 4×10⁻⁵in./in./degree F., and the thermal expansion of wood in the transversedirection, which is approximately 0.2×10-5 in./in./degree F. Dependingupon the proportions of the composite materials and the degree to whichthe components of polymer, interfacially modified particulate andinterfacially modified fiber are blended and uniform, the coefficient ofthermal expansion of the material can range from about 1.5 to 3.0×10⁻⁵preferably about 1.6 to 1.8×10-5 in./in./degree F.

The composite material displays a Young's modulus of at least 700 MPa,or in the range between 5,500 and 14,000 MPa.

FIGURES

FIGS. 1A and 1B show an isometric and side view of a building panel 100.The composite material 101 is disposed between cap-stock layers 102 and103. The building panel is formed with joinery means 104 and 105 thatcooperate to fix the panels in place. The building panel is also formedwith reinforcing elements 106 and 107. These reinforcing elements(larger element 106 smaller 107) also provide decorative detail to thepanel. The building a tongue 109 in groove 108 joinery means to alignthe panels in a wall or other structure.

In an embodiment, the composite material has a coating disposed thereon.For example, the composite material may be coextruded with a weatherresistant capstock (FIG. 1B, 102) which is resistant to ultra-violetlight degradation. One example of such a material is a polyvinylidenedifluoride composition. The capstock features a desirable surfacefinish, has the desired hardness and scratch resistance, and has anability to be colored by the use of readily available colorants.Preferably, the gauge thickness for the cap coat is-approximately 0.001to 0.100 inches across the siding surface, is preferably approximately0.02 inch. The capstock 35 is coextensive with at least the exposedsurfaces of the siding unit substrate and is tightly bonded thereto.

One suitable type of capstock is a DURACAP® polymer, manufactured by TheGeon Company, which is described in U.S. Pat. Nos. 4,183,777 and4,100,325. In addition, an AES-type polymer can be used (such as ROVEL®brand weatherable polymers manufactured by The Dow Chemical Company), oran ASA-type polymer can be used (such as GELOY® and CENTREX® polymersmanufactured by the General Electric Company and Monsanto,respectively). The capstock can be either coextruded with the substrateor laminated onto the substrate. In the preferred embodiment, thecapstock is coextruded. The coextrusion of the capstock polymer isaccomplished with dual-extrusion techniques, so that the capstock andsubstrate are formed as a single integral unit. Because the capstock maycontain colorants and pigments, no additional topcoating is necessary orrequired in the resulting structures. However, a coating of paint orother material may be applied if desired.

Besides a capstock, the outer layer 102 or 103 could be a veneer, a woodgrain covering, a pigmented covering, or another type of coextrudedlayer. In an embodiment, the outer surface 103 of the structural memberor panel 100 is smooth. However, the siding could feature decorativeindentations on the outer surface, for example, to resemble theappearance of wood. The texture can be produced by use of an embossingwheel, through which the siding passes after the extrusion process.

FIGS. 2A-2C show building panel structures 200, including compositematerial 201 and joinery, in the form of tongue and groove elements 203and 204. The building panel includes void spaces 202 that extend alongthe length of the panel and provide insulation value and weightreduction.

FIGS. 3A and 3B illustrate third and fourth embodiments 350, 351 of thesiding made from the composite material. Each siding unit 350, 351 hasthree portions: a central structural member that can be usedhorizontally or vertically, main portion 352 having an exposed frontface 360; an upper flange 355, 356; and a lower portion 356 having anotch 354. The difference between the embodiments of FIGS. 3A and 3B isthe construction of the upper flange 355, 356. The upper flange 355 inFIG. 3A is made of solid construction, whereas the upper flange 356 inFIGS. 3A and 3B has a thinner wall and reinforcing ribs 357. As is shownin FIGS. 3A and 3B, the main body portion 352 is hollow, which has a webstructure with three apertures 358.

The type of members 350,351 illustrated in FIGS. 3A and 3B may beapplied either horizontally or vertically. With this design, the nails359 are not hidden from view. Rather, each nail 359 passes through thelower web aperture of the main body portion 352 of the siding 350, 351.Preferably, the notch 354 provides for an overlap of approximately onehalf inch between the adjacent siding units. The lower edge 361 of onecourse's front face 360 is spaced above the upper edge 362 of the nextlower course, forming a groove 363 between adjacent courses of siding.This groove 363 can have various dimensions but in some embodiments isapproximately one inch wide.

FIG. 3B illustrates a fourth embodiment 465 of the siding. This type ofsiding 465 may also be applied either horizontally or vertically. Thesiding 465 has three portions, a central body portion 466, an uppernotch portion 467, and a lower notch portion 468. The central bodyportion 466 preferably has a web structure with a plurality (e.g.) atotal of five apertures, with (e.g.) three of the apertures 469 beingrelatively large and two of the apertures 470 being relatively small.Each of the apertures 470 accommodates a nail 471. In the embodimentillustrated, two nails 471 are applied in each course of siding 465. Theupper and lower notches 467, 468 are sized and configured such that theadjoining courses of siding 465 overlap. Preferably, each lower notchhas a mitered portion 472, which abuts against a mitered portion 473 inthe upper web of the main body portion. These mitered portions 472, 473form a V-shaped groove 474. The composite material has equalapplicability to siding systems in which the panels are installed orpositioned vertically.—As described above, the embodiments of FIGS. 3Aand 3B may be installed in a vertical manner. In addition, verticalsiding units made of the inventive composite material may be of ashiplap or a tongue-and-groove type, or plain boards of the compositematerial may be applied in one of several ways, such as board andbatten; board and board; and batten and board in structural ornon-structural applications.

FIG. 5 illustrates a fifth embodiment, in which solid structural membersin a board and batten construction is employed. The siding 576 has aplurality of vertically extending boards 577, and a plurality ofvertically extending battens 578. The composite material is used forboth the board 577 and batten 578 components of the siding 576. Nails579 pass through both the boards 577 and the battens 578. In theembodiment shown, both the board and batten are made of a solid lengthof composite material. However, the board and/or batten could be made ofa hollow, webbed construction as illustrated with the other embodiments.In addition, the solid siding members could be made of a foamedcomposite material.

FIGS. 6-8 illustrate alternative siding profiles 610, 720, i.e., theseventh, eighth and ninth embodiments of the siding unit. These designshave a non-curved, more rectilinear but pleasing appearance. Theprofiles 610, 720 each have a unique interlock mechanism for connectingadjoining siding units. The embodiments of FIGS. 6-8 are suitable forvertical siding installations.

In FIG. 6 a tongue 611 engages notch 612 defined by hook portion 613. Inthis matter, adjacent courses of siding 610 are interconnected and heldin place. Preferably, the flange 614 adjacent to hook 613 has a seriesof slots (not shown) through which nails 615 pass to engage with thesupport structure of the building (not shown). Because the flange 614 ispositioned behind the adjacent course of siding 610, the nails in flange614 are hidden from view. In the installation of siding 610, a firstcourse is installed and attached to the building using nails 615. Thenext course is started by inserting tongue 611 into notch 612 defined byhook 613. That next course is fastened using nail 615 and the process isrepeated for further vertical courses. In siding unit 610, the flange614 is made of solid construction whereas the main body 618 of the unit610 has a hollow structure. The main body portion 618 has hollowportions 616 which define a web structure. The siding unit has anoutwardly facing portion 619 a and an inwardly facing portion 619. Theweb's internal walls 617, 617 a provide structure and stability to theunit.

FIG. 7 shows an overlapping installation of the siding unit 720 overadjacent siding units 720. An overlapping joint 722 is formed betweenadjacent siding units 720. In the installation of the siding unit 720, afirst siding unit 720 is applied to a building surface and nailed intoplace using nails 723 that are directed through apertures 724. Thesecond course of siding unit 720 is then applied overlapping the firstcourse. A stop 721 butts against the upper portion 725 of the next lowerunit to provide the appropriate amount of overlap between the adjacentsiding units. Unit 720 has a hollow profile structure

FIG. 8 shows an alternative installation board and batten scheme. Boards830 are attached to a building surface using nails 832 directed throughapertures 833. Following the installation of a first board, other boardscan be installed leaving a gap 836 between courses of boards. The gaps836 between the boards 830 are covered using battens 831. Battens 831are attached to the siding system using nails 834 directed throughapertures 835 in the battens. In one installation scheme, all the boards830 are applied to the building surface prior to the installation of anybatten 831. In another installation scheme, two courses of boards 830can be applied to the building surface followed by one course of battens831. A further board 830 course is applied followed by the appropriatebatten 831 installation. The siding units shown in FIG. 8 aresubstantially rectilinear profiles that are made using the extrusion webtechnique. With any of these webbed embodiments, the hollow portions maycontain “dead air,” or the hollow portions may be filled with a suitablefoam material.

FIG. 9-11 shows a structural member 1100 using the composite material1101. The structural member is shown with a hollow or void interior1102. Such an interior contributes reduced weight and improvedinsulating value. The member 1100 can be used as dimensional structuralelements. The member can be used in framing, finishing, roofing,flooring, fenestration openings, or other building application. Themember can have an arbitrary width, and arbitrary thickness and anarbitrary length. A thickness of at least ½ inch can be used up to forexample 4 inches. Widths of 1 to 18 inches for example can be used.Typical construction material lengths are applicable for this number andcan range from 1 to 12 feet. Similarly, FIG. 10 shows a structuralmember 1200 having void spaces 1201, 1202, and 1203. Lastly, FIG. 11shows a solid structural member 1300 made of the composite.

FIG. 12 shows a hut or enclosure made from structural members andcomposite panels formed with the composite material. Enclosure 1400 ismade with a roof 1401 a base 1402. The roof and base can be made to thepanels were members shown in FIGS. 1-13 and can be joined conventionallywith fasteners or adhesives [not shown]. Enclosure 1400 is assembledfrom corner panel 1403 and side panel 1404 that are assembled withconventional fasteners or adhesives. Enclosure 1400 can include suchfenestration features such as an aperture for a door 1405 or window1406. FIG. 13 shows detail from a view of the portion of the wall fromthe closure of FIG. 12. FIG. 13 shows the assembly 1501 that combinesbase 1502 with vertical panel 1503, which vertical panel assembled fromdiscrete panels. Vertical panel 1503, in turn, is made from discretepanels that are joined at the joints 1504 a and 1504 b. Base 1502 is aL-shaped support structure 1505 upon which the panel 1503 is placed.Panel 1503 comprises an interior 1506 of the composite material, with aninterior and exterior cap-stock 1507 a and 1507 b for decorationpurposes. The panel can include joint reinforcements 1508, interiorpanel reinforcements 1509 a or 1509 b and base reinforcement 1510.

EXAMPLES Experimental Section

The interfacial modifier used in the following examples was titaniumtriisostearoylisopropoxide (KRTTS), CAS No. 61417-49-0, or a zirconatematerial, CAS No. 117101-65-2 neopentyl(diallyl) oxy-tri (dioctyl)phosphato-zirconate (NZ-12) (Kenrich Petrochemicals, Bayonne, N.J.).Other interfacial modifiers from KenRich and other suppliers may be usedas well to make the wood fiber composite with glass bubbles, glassparticles or other particulate.

Methods and Procedures Wood Fiber and Particle Characterizations

Wood fiber and particle characterization was completed to determinepacking behavior of the materials. Packing fraction was determined bydividing the packing density of the fiber and particle by the truedensity as determined via helium pycnometry. Packing fraction wasdefined as:

P_(f) = P_(d)/d_(pync)

wherein P_(f)=packing fraction; P_(d)=packing density andd_(pync)=pyncnometer density.

Packing density was determined by measuring the bulk fiber and/orparticle weight within a volume. The packing density was commonlydetermined by placing the fiber and/or particle within a metallurgicalpress. The press setup was available from Buehler International (LakeBluff, Ill.). For frangible materials, pressure was reduced to theappropriate level to reduce breakage of the particles thereby preventingartificially high packing density values. For very frangible materials,a tap density was used. The pycnometer density was determined by heliumgas pycnometry (AccuPync 1330 manufactured by MicromeriticsCorporation—Norcross, Ga.).

Compounding

The polymer and modified wood fiber and particles were fed inappropriate ratios using K-tron K₂O gravimetric weight loss feeders. Thewood fiber and particles were fused together within a 19 mm B&P twinscrew compounder. Barrel zone temperatures, screw speed, volumetricthroughput, and die characteristics (number of openings and openingdiameter) were varied depending on the nature of the fiber, particlesand polymers being compounded. Commonly, torque, pressure, and melttemperature were monitored responses. A useful way to ensure the properratio of polymer and particulate(s) was to place compounded pellets intothe heated metallurgical press forming a “puck”, the density of which isknown as the “puck density”.

Extrusion

The compounded products were extruded using 1″ diameter extruder (Al—BeIndustries, Fullerton, Calif.). Temperatures and volumetric throughputvary depending on the rheological behavior of the materials beingextruded. Typically, motor amp load and extrusion pressures weremonitored responses and used to gauge ease of extrudability. For samplesrequiring characterization of tensile properties, the materials wereextruded through a 19 mm×3 mm rectangular die plate onto a moving beltto minimize extrudate draw-down.

The following examples and data were developed to further illustrate theembodiments that were explained in detail above. The informationillustrates exemplary production conditions and composition for a pelletand a structural member or panel of the embodiment.

To make the composite material with a density of 1.17 g/cc, thecomponents of the composition were combined in the following table. Thewood fiber and particles were pre-treated with a coating of theinterfacial modifier using the procedures described in U.S. PatentApplication 2010/0279100 to produce a homogeneous and uniform, exteriorcoating on the particulate. As stated before, KRTTS or NZ-12 (KenrichPetrochemicals, Bayonne, N.J.) was used as the interfacial modifier. Theglass particles of beads, Potters 3000A were obtained from PottersIndustries (Valley Forge, Pa.). The softwood fiber was obtained fromvarious local millwork manufacturers in Minnesota. The hardwood fiberMaple 4010 was obtained from American Wood Fiber (Schofield, Wis.). Thepolyvinyl chloride and poly lactic acid polymers used were obtained fromPolyOne (Avon Lake, Ohio) and NatureWorks (Minnetonka, Minn.),respectively.

All particulate, wood fiber and glass mixed dispersed particulate werecoated uniformly with the interfacial modifier. The coated particulatewas mixed with the polyvinyl chloride polymer in a B&P co-rotating 19 mmtwin screw compounder with a particle feed rate of 17.38 g/min and apolymer feed rate of 34.08 g/min with a resulting particle to mass ratioof 1.96. The particulate that was uncoated with interfacial modifier,labeled “None” in Table 1, was identical in other components of thecomposition such as wood fiber loading and identity, glass bead loadingand identity, and polymer loading and identity.

Examples 1-4B

TABLE 1 IM Loading IM Type Level on Polymer Polymer on ParticlesParticle- Particle- Particle- Particle- Examples Type V(f) Particles(pph) 1 Type 1 V(f) 2 Type 2 V(f) Comparative PVC 50% None 0.00Softwood- 50.0% None None 1 80 mesh 1A PVC 50% Zirconate 5.00 Softwood-50.0% None None 80 mesh 1B PVC 50% Titanate 5.00 Softwood- 50.0% NoneNone 80 mesh Comparative PVC 50% None 0.00 Softwood- 42.5% SGB 7.5% 2 80mesh 2A PVC 50% Zirconate 4.16 Softwood- 42.5% SGB 7.5% 80 mesh 2B PVC50% Titanate 4.16 Softwood- 42.5% SGB 7.5% 80 mesh Comparative PLA 45%None 0.00 Softwood- 46.8% SGB 8.3% 3 80 mesh 3A PLA 45% Titanate 4.16Softwood- 46.8% SGB 8.3% 80 mesh Comparative PLA 55% None 0.00 Softwood-45.0% None None 4 80 mesh Comparative PLA 55% Titanate 5.00 Softwood-45.0% None None 4A 80 mesh Comparative PLA 55% Zirconate 5.00 Softwood-45.0% None None 4B 80 mesh Polymer Type-PVC-87180 from PolyOne(AvonLake, OH), PLA-Biopolymer—4043D from NatureWorks (Minnetonka, MN). IMtype-an organo-titanate material KRTTS-titaniumtriisostearoylisopropoxide, anorgano-zirconate material,neopentyl(diallyl) oxy-tri (dioctyl) phosphato-zirconate—NZ12 (KenrichPetrochemicals, Bayonne, NJ). Cellulosic Particle (Particle1)—Softwood-80 mesh, from various local millwork manufacturers; Hardwood40 mesh Maple 4010, American Wood Fiber (Schofield, WI). SGB Solid GlassBead (Particle 2)—Potters 3000A, Potter Industries (Valley Forge, PA)

TABLE 2 Flexural Properties Extrusion Flexural Stress Motor FlexuralStrain @ Max Compounding % Torque Pressure Load MFA Modulus @ LoadExamples Low High (psig) (Amps) (sec/10 cc) (MPa) Break (MPa)Comparative 25 35 1360 3.7 135.3 5759.4 X 51.688 1 1A 20 30 530 2.8 32.34210.8 1.15X 42.416 1B 20 30 820 3.0 23.5 3452.2 1.3X 34.062 Comparative30 40 1250 4.3 121.0 5491.6 X 47.772 2 2A 20 30 670 3.5 56.3 3892.8 1.4X37.808 2B 20 25 485 3.5 44.8 3185.6 1.4X 32.442 Comparative 55 65 10853.6 22.9 NR NR NR 3 3A 45 55 835 3.4 5.6 NR NR NR Comparative 45 50 3503.2 10.3 NR NR NR 4 Comparative 50 60 NR NR 46.8 NR NR NR 4A Comparative50 60 360 3.2 11.2 NR NR NR 4B

The composite materials of Table 2 were tested with the followingmodifications to ASTM D790-10 for flexural properties. The extrudedwidth of all specimens was tested in a range of 18.80 mm to 19.20 mmwith a depth of 3.25 to 3.45 mm. Per the standard, the test specimen wasthicker than 3.2 mm (which is the situation here), the width wassupposed to not exceed ¼^(th) the support span, but it did. The supportspan=16×thickness=16×3.45=55.2 mm while the specimens averaged 19 mm:19/55.2=34.4% of the span which was 9.4% wider than the 25% maximumwidth per the standard. This modification was done since the edgeeffects of a narrower cut sample would have most certainly skewed thecollected information. All samples had a similar cross section and niceedges from being extruded through the die.

The second modification was in the overall displacement of the sampleduring the test. D790 specifies that the test be terminated after 5%maximum strain of the outer fiber surface. Such a termination would meanthat the test be terminated after 0.05*3.45=0.17 mm. The compliance ofour materials required us to test beyond the maximum displacement statedin the test since our differentiation did not occur until after muchhigher displacements and strain levels.

Melt flow analysis (MFA) of the composite material was performed using aModel 50 Mini-Jector from Miniature Plastics Molding (MPM) (Solon,Ohio). The unit was modified with sensor(s) to monitoring a variety ofMini-Jector conditions such as hydraulic fluid pressure, hydraulicpiston displacement, ram force, and time.

Melt flow analysis and measurement of the composite material arepredictive of the flow characteristics of highly filled and/orreinforced polymeric materials. Melt flow analysis measurements are madeunder known temperatures and applied pressures/forces causing the testedmaterial to flow past the MPM spreader, through the nozzle tip chambers,and then out the non-drool nozzle of the MPM Mini-Jector to atmosphericpressure in the purging fixture. The mass of material that flows throughthe Mini-Jector per unit of time is a direct measure of the rheologicalproperties of the tested material under conditions similar to injectionmolding or process extrusion. Using any of a variety of densitymeasurements of the analyzed materials, the melt flow analysis data canalso be converted to time/volume units.

The data in Table 2 shows that interfacial modifying chemistry appliedto a fiber and particle reveals 1) favorable rheological properties asseen throughout compounding, extrusion, and 2) the MFA measuring withincreasing resolution and differentiation from compounding throughextrusion. Some of the enhanced viscoelastic properties andimmiscibility between the polymer, particle and fiber are indicatedby 1) lower stress at max load, 2) reduced flexural modulus, and 3)increased flexural displacement at break.

In an embodiment, flexural modulus of the composite material, asmeasured by ASTM D790 will exhibit improved flexural modulus incomparison to composite materials made with particulate that is notcoated with an interfacial modifier. By way of example, the flexuralmodulus for a composite material in accordance with embodiments hereinwill be 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% less thanotherwise identical compositions made with particulate that is notcoated with the interfacial modifier. Similar properties for thecomposite material may be seen in extrusion pressure.

In order to effectively capture the differences, a ratio of flexuraldisplacement for the modified materials vs. that of the unmodifiedcontrol was generated and calculated for each scenario.

Pellets of composite material were made for Example 5. The compositematerial had the following properties as listed in Table 3 and thefollowing properties as listed in Table 4.

TABLE 3 Component Vol % Wt. % Polymer PVC 87180 (PolyOne); 60.03 66.26Density 1.420 g/cc Particulate Wood 75 wt. % of particulate component20.9  24.10 Glass Bubbles 25 wt. % of particulate component 15.9   8.03Interfacial 5 pph of particulate component 3.2  1.61 Modifier

TABLE 4 Polymer/Wood Fiber/Glass Bubbles Testing Property CompositeProtocol Observations Specific Gravity 1.17 g/cc Puck density or Gaspycnometry as described Gas pycnometry as described Flame Resistance 0UL 94 Did not sustain flame Water Vapor 1.22% % Wt. gain Uptake per 72hours Liquid Water 1.75% ASTM D570  % Wt. gain Uptake per 72 hoursImpact Strength 13.0 j/cm ASTM D5420 Flexural Modulus 2900 MPa ASTMD790  Supported flat sample Flexural Strength 23 Pa ASTM D790  at YieldFlexural Strength 45 Pa ASTM D790  at Break Tensile Modulus  700 MPaASTM D638  Tensile Strength  15 MPa ASTM D638  at Yield Tensile Strength 17 MPa ASTM D638  at Break k-value 0.20 W/m-k Lee’s Disk Apparatus

Example 5A—Young's Modulus Test Results

The Young's modulus was measured using a Lloyd's Instrument (AMLETEK,Largo Fla.) software automated materials testing system and an ASTMmethod D-638. Specimens were made according to the test.

The pellet of the composite material displays a Young's modulus of atleast 700 Mpa and commonly falls in the range between 600 and 5000 MPa.

The Young's modulus for the polyvinyl chloride compound, was measuredsimilarly to the composite material, was 3000 MPa.

Lengths of the structural member or panel was manufactured and testedfor coefficient of thermal expansion, thermal conductivity, decay,corrosion, heat distortion temperature, water absorption, moistureexpansion, and compression load. For many of these characteristics, thecomposite structural member or panel was compared to siding manufacturedwith conventional siding materials.

The following tables display the test data developed in theseexperiments and obtained from published sources. The material of thesiding unit was indicated by the designation “Fiber/Glass Bubble PolymerComposite” in the Examples below. This “Fiber/Glass Bubble PolymerComposite” composite material was made of 66 wt-% polyvinyl chloride and24 wt. % interfacially modified coated fiber derived from a hard or softwood as shown in Table 3.

Using the methods for manufacturing and extruding the pellet, astructural member or panel as illustrated in FIGS. 1-11 is manufacturedusing an appropriate extruder die. The melt temperature of the input tothe machine is 390-420° F. A vacuum is pulled on the melt mass of noless that 3 inches mercury. The overall width of the unit is about 2.0inches. The wall thickness of any of the elements of the extrudate isabout 0.10 inch.

Several-different siding materials were tested and/or analyzed, as shownon the tables below. The data for the five types of siding materials,other than the composite material, was obtained from published sources.For aluminum, the data was obtained from Metals Handbook, Vol. 2, 9thEd., American Society for Metals, 1990. For PVC, the data was obtainedfrom the specifications and product literature for PVC siding which wasmanufactured by Reynolds Metals Company of Richmond, Va. For cedar, thedata was obtained from Forest Products and Wood Science, J. G. Haygreenand J. L. Bowyer, The Iowa State University Press, 1982. For MASONITE®the data was obtained from the specifications and product literature forMASONITE® siding obtained from MASONITE® Corporation of Chicago, Ill.(The MASONITE® material is a fiber board material made from hard woodfibers and cement binders.) The data for steel was obtained from MetalsHandbook, Vol. 1, 9th Ed., American Society for Metals, 1990.

Example 5B—Coefficient of Thermal Expansion Tests

The strain due to a 1° temperature change was known as the coefficientof thermal expansion (COTE). The deformation per unit length in anydirection or dimension was called strain.

The coefficient of thermal expansion was measured for the compositesiding and for the PVC siding using ASTM Test Method D696. The data forthe other materials was obtained from the above published sources.

COTE Material (in./in./.degree. F.) Fiber/Glass Bubble 3.69 × 10⁻⁶Polymer Composite Aluminum 12.1 × 10⁻⁶ PVC   36 × 10⁻⁶ Cedar 3 to 5 ×10⁻⁶  MASONITE ®   <3 × 10⁻⁶ Steel   12 × 10⁻⁶

The above table shows that the coefficient of thermal expansion for thecomposite material for the structural member or panel was significantlyless than the coefficient of thermal expansion for PVC siding, aluminum,and steel. The composite's coefficient of thermal expansion was similarto that of cedar and MASONITE® siding.

Example 5C—Thermal Conductivity Tests

Thermal conductivity was the ratio of the steady-state heat flow (heattransfer per unit area per unit time) along the rod to the temperaturegradient along the rod. Thermal conductivity indicates the ability of amaterial to transfer heat from one surface to another surface.

The thermal conductivity of the composite siding and the PVC was testedusing ASTM Test Method F433. The data for the other materials wasobtained from the above published sources.

Thermal Conductivity Material (W/mK) Fiber/Glass Bubble  0.17 PolymerComposite Aluminum  0.173 PVC  0.11 Cedar  0.09 MASONITE ® N/A Steel59.5 

The above table shows that the thermal conductivity of the compositematerial was slightly more than that of the PVC siding, about the sameas aluminum, and significantly less than steel. (The thermalconductivity of MASONITE® was not tested.)

Example 5D—Heat Distortion Temperature Tests

The heat distortion temperature was the point at which the materialbegins to warp or become distended. The composite and PVC siding wastested pursuant to ASTM Test Method D648. There was no data given forthe metals, because the other materials do not distort until anextremely high temperature was reached. The heat distortion temperaturefor the composite material was higher than the heat distortiontemperature for PVC. (The heat distortion temperature was not measuredfor those materials having an “N/A” value.)

Example 5E—Moisture Expansion and Water Absorption Test Results

The materials were evaluated with respect to their propensity to expandwhen subjected to water. The composite and PVC siding were tested formoisture absorption pursuant to ASTM Test Method D570-84. The metalmaterials were designated “None”, because the metals do not absorbwater. Cedar was designated “Yes,” because it does absorb water and doeshave a tendency to expand. PVC was designated “N/A,” because PVC's waterabsorption was so low as to not be measurable.

Moisture Water Material Expansion Absorption Fiber/Glass Bubble NA  1.1%Polymer Composite Aluminum No None PVC No N/A Cedar Yes  >100% MASONITE ® Yes   12% Steel No NoneThe above table shows that the composite material has a lower waterabsorption than cedar and MASONITE®.

Example 5F—Decay and Corrosion Test Results

The materials, Fiber/Glass Bubble Polymer Composite, PVC, Aluminum,Cedar, MASONITE® and steel, were evaluated with respect to theirpropensity to show decay and corrosion. None of the materials show decayand the Fiber/Glass Bubble Composite was equivalent to aluminum andsteel in corrosion performance.

Example 5G—Impact Testing

The determination of the resistance of impact of the main profiles by afalling mass is determined by the following procedure. This procedure isa modification of the Gardner Drop Dart protocol—ASTM 5420.

After testing, the profiles are visually examined for failures whichappear at the point of impact. Main profile typically refers to anextruded piece having load bearing functions in a construction such as awindow or door. The test surface, sight surface or face surface of theprofile is a surface exposed to view when the window is closed. Thefalling weight, the dart, impacts the face surface, sight surface orexposed surface. A web typically refers to a membrane which can be rigidor non-rigid connecting two walls of the main profile.

One or more test pieces are made by sawing appropriate lengths fromtypical composite material production profile extrusion pieces. The testpieces are conditioned at a temperature of about 21.1+/−.0.2° C. for atleast one hour prior to testing. Each test piece is tested within 10seconds of removal from the conditioning chamber to ensure that thetemperature of the piece did not change substantially.

The profile is exposed to the impact from the falling dart mass onto thesight surface, face surface or exposed surface of the profile. Such asurface is the surface designed to be exposed to the weather. Thefalling mass is dropped directly onto the sight surface at a pointmidway between the supporting webs. The profile is to be adjusted withrespect to the falling mass such that the falling mass strikes in adirection normal to the surface of the test face.

The results of the testing are shown by tabulating the number of testpieces tested, the number of pieces broken or if not broken, the depthof any defect produced in the profile by the test mass.

The composite materials resistance to denting is better than each of thefive materials tested, except for MASONITE®. The composite materialsdent resistance is significantly better than aluminum and PVC. (Noreading could be obtained from the aluminum specimen, because ofbreakage of the aluminum profile.)

Example 6

The hardwood or softwood particulate from American Wood Fiber and glassparticulates from Potters, the dispersed mixed particulate, is firsttreated with an interfacial modifier such as NZ12. This is done bydissolving the desired amount of the interfacial modifier in a 250 mlbeaker containing 50 ml of solvent (usually isopropyl, or some other,alcohol) and then adding 100 grams of mixed particulate into the beaker.The resulting slurry is then heated to an appropriate temperature suchas for example a 100° C. and until the mixture can no longer be stirredand most of the solvent has been driven off. The beaker containing themixed particulate with interfacial modifier is then placed in a forcedair oven for drying for a time and temperature, such as, for example 30minutes at 100° C. The treated mixed particulate is then added to a 100ml beaker containing a solution of THV220A dissolved in acetone. THV220Ais a polymer of tetrafluoroethylene, hexafluoropropylene, and vinylidenefluoride available from 3M (St. Paul, Minn.). The mixture is then heatedto a temperature, such as, for example, to 30° C. and continuouslystirred until most of the acetone has evaporated. The composite materialis then placed in a forced air oven for a time, such as, for example, 30minutes at 100° C.

After drying, the composite material is prepared and tested forproperties as in the previous examples. Extrusion, impact, flameresistance, k-value, water uptake, tensile properties, and flexuralproperties are properties that are measured to uncoated or non-IMtreated particles.

Example 7

The glass fiber from, for example, Pittsburgh Plate Glass (Pittsburgh,Pa.) and glass particulates from Potters, the dispersed glassparticulate, is first treated with an interfacial modifier such as NZ12.This is done by dissolving the desired amount of the interfacialmodifier in a 250 ml beaker containing 50 ml of solvent (usuallyisopropyl, or some other, alcohol) and then adding 100 grams of theglass particulate into the beaker. The resulting slurry is then heatedto an appropriate temperature such as for example a 100° C. and untilthe mixture can no longer be stirred and most of the solvent has beendriven off. The beaker containing the glass particulate with interfacialmodifier is then placed in a forced air oven for drying for a time andtemperature, such as, for example, 30 minutes at 100° C. The treatedmixed particulate is then added to a 100 ml beaker containing a solutionof such as, for example, THV220A dissolved in acetone. THV220A is apolymer of tetrafluoroethylene, hexafluoropropylene, and vinylidenefluoride available from 3M (St. Paul, Minn.). Other polymers such as forexample PLA and PVC may also be useful depending on the function andstructural of the final article or shape. The mixture is then heated toa temperature, such as, for example, to 30° C. and continuously stirreduntil most of the acetone has evaporated. The composite material is thenplaced in a forced air oven for a time such as, for example, 30 minutesat 100° C.

After drying, the composite material is prepared and tested forproperties as in the previous examples. Extrusion, impact, flameresistance, k-value, water uptake, tensile properties, and flexuralproperties are properties that are measured in comparison to uncoated ornon-IM treated particles.

While the above specification shows an enabling disclosure of thecomposite material, other embodiments can be made without departing fromthe spirit and scope of the invention. Accordingly, the invention isembodied in the claims hereinafter appended.

It should be noted that, as used in this specification and the appendedclaims, the singular forms “a,” “an,” and “the” include plural referentsunless the content clearly dictates otherwise. Thus, for example,reference to a composition containing “a compound” includes a mixture oftwo or more compounds. It should also be noted that the term “or” isgenerally employed in its sense including “and/or” unless the contentclearly dictates otherwise.

It should also be noted that, as used in this specification and theappended claims, the phrase “configured” describes a system, apparatus,or other structure that is constructed or configured to perform aparticular task or adopt a particular configuration to. The phrase“configured” can be used interchangeably with other similar phrases suchas arranged and configured, constructed and arranged, constructed,manufactured and arranged, and the like.

All publications and patent applications in this specification areindicative of the level of ordinary skill in the art to which thisinvention pertains. All publications and patent applications are hereinincorporated by reference to the same extent as if each individualpublication or patent application was specifically and individuallyindicated by reference.

1-96. (canceled)
 97. A thermoplastic composite comprising: a. about 90to 5 vol. % of a polymer phase comprising a thermoplastic polymer with adensity of less than about 1.9 g-cm⁻³ and b. about 10 to 95 vol. % of adispersed fiber phase comprising a reinforcing fiber with an aspectratio of 1 to 50 the dispersed phase comprising about 0.2-6 wt. % of acoating of at least one interfacial modifier; wherein the compositematerial has a Young's modulus of greater than 700 MPa; the interfacialmodifier provides a coating on the dispersed fiber that can form a closeassociation between the fiber and polymer and covalent bonding betweenfiber and polymer is not formed.
 98. The composite material of claim 97wherein the reinforcing fiber comprises a wood fiber.
 99. The compositematerial of claim 97 wherein the reinforcing fiber comprises a glassfiber.
 100. The composite material of claim 97 wherein the compositefurther comprises a hollow glass sphere or a solid glass particulate.101. A pellet comprising a thermoplastic composite comprising: a. about90 to 5 vol. % of a polymer phase comprising a thermoplastic polymerwith a density of less than about 1.9 g-cm⁻³ and b. about 10 to 95 vol.% of a dispersed fiber phase comprising a reinforcing fiber with anaspect ratio of 1 to 50 the dispersed phase comprising about 0.2-6 wt. %of a coating of at least one interfacial modifier; wherein the compositematerial has a Young's modulus of greater than 700 MPa; the interfacialmodifier provides a coating on the dispersed fiber that can form a closeassociation between the fiber and polymer and covalent bonding betweenfiber and polymer is not formed.
 102. The composite material of claim101 wherein the reinforcing fiber comprises a glass fiber.
 103. Thecomposite material of claim 101 wherein the composite further comprisesa hollow glass sphere or a solid glass particulate.
 104. The pellet ofclaim 101 forming a structural decking.
 105. The pellet of claim 101forming an extruded panel member.
 106. The pellet of claim 101 forming astructural fencing member.
 107. The pellet of claim 101 forming at leasttwo extruded panels and joinery features.
 108. The pellet of claim 101comprising a fenestration opening.
 109. A composite adapted for use inan injection molding system, the composite for the injection moldingsystem comprising: a. about 90 to 5 vol. % of a polymer phase comprisinga thermoplastic polymer with a density of less than about 1.9 g-cm⁻³ andb. about 10 to 95 vol. % of a dispersed fiber phase comprising areinforcing fiber with an aspect ratio of 1 to 50 the dispersed phasecomprising about 0.2-6 wt. % of a coating of at least one interfacialmodifier; wherein the composite material has a Young's modulus ofgreater than 700 MPa; the interfacial modifier provides a coating on thedispersed fiber that can form a close association between the fiber andpolymer and covalent bonding between fiber and polymer is not formed.110. The composite of claim 109 wherein the composite comprises acellulosic fiber.
 111. The composite of claim 109 wherein thereinforcing fiber comprises a wood fiber.
 112. The composite material ofclaim 109 wherein the reinforcing fiber comprises a glass fiber. 113.The composite material of claim 109 wherein the composite furthercomprises a hollow glass sphere or a solid glass particulate.